EP16K Controller

Service Manual
MC/FC
Controller Benjamin Gerpe Finez
Mantenimineto Industrial Gerpe SL
Pol. Ind. Los Pinares parcela 7
EP16K ETB6A-00011-up 49530 Coreses / Zamora
Zamora
Spain
EP18K ETB6A-50001-up
Email address:
info@migerpe.com
EP20KC ETB7A-00011-up
For use with EP16K-EP20KC Chassis Service Manual. 99759-69100

FOREWORD
This service manual is a guide to servicing of Cat® lift trucks. The instructions are grouped by
systems to serve the convenience of your ready reference.
Long productive life of your lift trucks depends to a great extent on correct servicing — the
servicing consistent with what you will learn from this service manual. We hope you read the
respective sections of this manual carefully and know all the components you will work on
before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual were of the trucks of
serial numbers in effect at the time it was approved for printing. Cat lift truck reserves the right
to change specifications or design without notice and without incurring obligation.
Safety Related Signs
The following safety related signs are used in this service

manual to emphasize important and critical instructions:
Indicate a specific potential hazard

! WARNING resulting in serious bodily injury or
death.
Indicate a specific potential hazard

! CAUTION
resulting in bodily injury, or damage
to, or destruction of, the machine.
Indicates a condition that can cause

NOTE
damage to, or shorten service life of,
the machine.
Pub. No. 99759-69100

! WARNING
SAFETY
! WARNING ! WARNING
The proper and safe lubrication and Do not operate this truck unless you have read
maintenance for this lift truck, recommended and understand the instructions in the
by Cat lift truck, are outlined in the OPERATION OPERATION & MAINTENANCE MANUAL.
& MAINTENANCE MANUAL for these trucks. Improper truck operation is dangerous and
Improper performance of lubrication or could result in injury or death.
maintenance procedures is dangerous and
could result in injury or death. Read and 4. Lower the forks or other implements to the ground
understand the OPERATION & MAINTENANCE before performing any work on the truck. If this
MANUAL before performing any lubrication or cannot be done, make sure the forks or other
maintenance. implements are blocked correctly to prevent them
from dropping unexpectedly.
The serviceman or mechanic may be unfamiliar with 5. Use steps and grab handles (if applicable) when
many of the systems on this truck. This makes it mounting or dismounting a truck. Clean any mud
important to use caution when performing service or debris from steps, walkways or work platforms
work. A knowledge of the system and/or components before using. Always face truck when using steps,
is important before the removal or disassembly of any ladders and walkways. When it is not possible to
component. use the designed access system, provide ladders,
Because of the size of some of the truck components, scaffolds, or work platforms to perform safe repair
the serviceman or mechanic should check the weights operations.
noted in this Manual. Use proper lifting procedures 6. To avoid back injury, use a hoist when lifting
when removing any components. components which weigh 23 kg (50 lb.) or more.
Following is a list of basic precautions that should Make sure all chains, hooks, slings, etc., are in
always be observed. good condition and are of the correct capacity. Be
1. Read and understand all warning plates and decals sure hooks are positioned correctly. Lifting eyes
on the truck before operating, lubricating or are not to be side loaded during a lifting operation.
repairing the product. 7. To avoid burns, be alert for hot parts on trucks
2. Always wear protective glasses and protective which have just been stopped and hot fluids in
shoes when working around trucks. In particular, lines, tubes and compartments.
wear protective glasses when pounding on any part 8. Be careful when removing cover plates. Gradually
of the truck or its attachments with a hammer or back off the last two bolts or nuts located at
sledge. Use welders gloves, hood/goggles, apron opposite ends of the cover or device and pry cover
and other protective clothing appropriate to the loose to relieve any spring or other pressure, before
welding job being performed. Do not wear loose- removing the last two bolts or nuts completely.
fitting or torn clothing. Remove all rings from 9. Be careful when removing filler caps, breathers and
fingers when working on machinery. plugs on the truck. Hold a rag over the cap or plug
3. Do not work on any truck that is supported only by to prevent being sprayed or splashed by liquids
lift jacks or a hoist. Always use blocks or jack under pressure. The danger is even greater if the
stands to support the truck before performing any truck has just been stopped because fluids can be
disassembly. hot.
10. Always use tools that are in good condition and be 19. Tighten connections to the correct torque. Make
sure you understand how to use them before sure that all heat shields, clamps and guards are
performing any service work. installed correctly to avoid excessive heat, vibration
11. Reinstall all fasteners with same part number. Do or rubbing against other parts during operation.
not use a lesser quality fastener if replacements are Shields that protect against oil spray onto hot
necessary. exhaust components in event of a line, tube or seal
failure, must be installed correctly.
12. If possible, make all repairs with the truck parked
on a level, hard surface. Block truck so it does not 20. Relieve all pressure in air, oil or water systems
roll while working on or under truck. before any lines, fittings or related items are
disconnected or removed. Always make sure all
13. Disconnect battery and discharge any capacitors
raised components are blocked correctly and be
(electric trucks) before starting to work on truck.
alert for possible pressure when disconnecting any
Hang “Do not Operate” tag in the Operator’s
device from a system that utilizes pressure.
Compartment.
21. Do not operate a truck if any rotating part is
14. Repairs, which require welding, should be
damaged or contacts any other part during
performed only with the benefit of the appropriate
operation. Any high speed rotating component that
reference information and by personnel adequately
has been damaged or altered should be checked for
trained and knowledgeable in welding procedures.
balance before reusing.
Determine type of metal being welded and select
correct welding procedure and electrodes, rods or 22. When handling the parts containing asbestos, be
wire to provide a weld metal strength equivalent at careful not to inhale the asbestos. Doing so is
least to that of parent metal. hazardous to your health.
15. Do not damage wiring during removal operations. If the shop dust may contain asbestos, follow the
Reinstall the wiring so it is not damaged nor will it precautions described below.
be damaged in operation by contacting sharp a. Do not use compressed air for cleaning.
corners, or by rubbing against some object or hot b. Do not brush or apply grinder on asbestos
surface. Place wiring away from oil pipe. containing materials.
16. Be sure all protective devices including guards and c. To clean asbestos containing materials, wipe
shields are properly installed and functioning with moistened cloth or use a vacuum cleaner
correctly before starting a repair. If a guard or with particle filter.
shield must be removed to perform the repair work,
d. If you have to handle the parts containing
use extra caution.
asbestos for a long time, be sure to do it in a
17. Always support the mast and carriage to keep well-ventilated area.
carriage or attachments raised when maintenance
e. If the asbestos in the air cannot be removed,
or repair work is performed, which requires the
wear a mask.
mast in the raised position.
f. Be sure to observe the working rules and
18. Loose or damaged fuel, lubricant and hydraulic
regulations.
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which g. When disposing of materials with asbestos, be
have been bent or damaged. Inspect lines, tubes sure to observe the environmental protection
and hoses carefully. Do not check for leaks with regulations of your area.
your hands. Pin hole (very small) leaks can result h. Avoid working in the atmosphere where
in a high velocity oil stream that will be invisible asbestos particles may be suspended.
close to the hose. This oil can penetrate the skin
and cause personal injury. Use cardboard or paper
to locate pin hole leaks.
HOW TO USE THIS MANUAL
(Removal, Installation, Assembly and Disassembly)
Disassembly diagram (example)
Procedures are described in the text.

Disassembling sequence
209603
Sequence
1 Cover , Bolt, Washer (part name)
2 Snap ring ................ (part name)
Suggestion for disassembling

1. Output shaft, Removing
Remove output shaft using a special tool.
209604
Service Data
0.11 to 0.28 mm
A
Gear Backlash (0.0043 to 0.0110 in.)
B 0.5 mm (0.020 in.)
A: Standard Value
B: Repair or Service Limit
Symbols or abbreviation
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
Units
1. SI Units are used in this manual.
2. The following table shows the conversion of SI unit and customary unit.
Item SI unit Customary unit

1N 0.1020 kgf
Force
(1 lbf) (0.4536 kgf)
1 kPa 0.0102 kgf/cm2
Pressure
(1 psi) (0.0703 kgf/cm2)
1 N·m 0.1020 kgf·m
Torque
(1 lbf·ft) (0.1383 kgf·m)
GROUP INDEX
GROUP INDEX Items
Outline, Controller components, Logic card components, Controller models,

Operation outline, Drive system, Hydraulic system, Fail-safe system,
MAIN CONTROLLER
Malfunction detection, Malfunction data record, Setting, Self-diagnosis, etc.
1
TROUBLESHOOTING
Faulty central vehicle monitor system, Faulty diagnosis indication,
FOR CONTROL 2
or Other abnormalities
CIRCUITS
Motor installation positions, Specifications, Structures, Tightening of high-power

MOTORS cable terminals, Inspection of brushes for wear and brush replacement, 3
Procedures and suggestions for removal and installation, etc.
MAIN CONTROLLER
Outline ....................................................................................................... 1– 1
Controller Components (Part 1) ......................................................... 1– 2 1
Controller Components (Part 2) ......................................................... 1– 3
Logic Card Components ...................................................................... 1– 4
Controller Models ................................................................................... 1– 5
Operation Outline ................................................................................... 1– 6
Drive System ........................................................................................... 1– 6
Neutral Position ........................................................................................ 1 – 6
Powering ................................................................................................... 1 – 6
Drive Motor’s Current Table ....................................................................... 1 – 7
Regeneration ............................................................................................ 1 – 9
Lever Regeneration Characteristic ............................................................ 1 – 10
Auto Regeneration Characteristic ............................................................. 1 – 11
Hydraulic System ................................................................................... 1 – 12
Manual Control Model ............................................................................... 1 – 12
Finger-tip Control Model ........................................................................... 1 – 12
Fail-safe System ..................................................................................... 1 – 13
Output Power Control at Low Battery Voltage ........................................... 1 – 13
Overheat ................................................................................................... 1 – 14
Brush Wear ............................................................................................... 1 – 14
Maximum Vehicle Speed Control (SUO #7) .............................................. 1 – 14
Output Power Control During Braking ....................................................... 1 – 14
Chat Timer (SUO #24) .............................................................................. 1 – 14
Seat Switch Timer (SUO #25) ................................................................... 1 – 14
Malfunction Detection (Run Time Diagnosis) ................................. 1 – 14
Malfunction Data Record (History Folder) ....................................... 1 – 15
Data Storage ............................................................................................ 1 – 15
Review of Stored Data .............................................................................. 1 – 15
Setting ....................................................................................................... 1 – 15
Printed Circuit Board Settings ................................................................... 1 – 15
Adjustment of Remaining Battery Level .................................................... 1 – 15
Setup Options ........................................................................................... 1 – 16
Self-diagnosis ......................................................................................... 1 – 16
Other Functions ...................................................................................... 1 – 17
Display Unit .............................................................................................. 1 – 17
BDI (Battery Discharge Indicator) ............................................................. 1 – 17
Hourmeters and Time Display ................................................................... 1 – 17
Vehicle Speed and Error Code Display ..................................................... 1 – 18
Action Lights (LEDs) ................................................................................. 1 – 18
Inspection and Adjustment ................................................................. 1 – 26
Inspection and Adjustment Tools .............................................................. 1 – 26
Removal and Installation of Logic Card ..................................................... 1 – 26
Tightening of High-tension Cable Terminals .............................................. 1 – 27
Component Testing ................................................................................... 1 – 28
Service Data ............................................................................................ 1 – 69
Tightening Torque .................................................................................. 1 – 73
MAIN CONTROLLER
Outline
Main controller
The main controller is the heart of the lift truck operating
system.
The logic card contains decision making functions, and is
equipped with a battery discharge indicator and a
malfunction diagnostic function.
The main controller is used to operate the drive motors,
pump motor and power steering system.
206793A
Logic card
The logic card is a printed circuit board located on the main
controller panel. Most of the circuits on the board are used
to control input and output voltages to and from the
microprocessor.
Microprocessor (MPU)
The software in the microprocessor controls the drive
system, pump motor and central vehicle monitor system
(CVMS).
Selector Switches
They are used for setting the BDI and section of some
options.
206794
1-1
MAIN CONTROLLER
Controller Components (Part 1)
2
1
3 5 8 4 7 6
206795A
1 Logic card 6 Line contactor

2 Head capacitors 7 Line fuse (500 A)
3 Current sensor 8 DRS switch (for malfunction diagnosis and
4 Regeneration contactor program option setting)
5 Lift fuse (325 A) 9 Power steering fuse (50 A)
1-2
MAIN CONTROLLER
Controller Components (Part 2)
206796
1 Hydraulic system diode (D1P) 5 Drive system IGBT (T1R)

2 Drive system diode (D1L) 6 Hydraulic system IGBT (T1P)
3 Drive system diode (D1R) 7 Regeneration system diode (D2)
4 Drive system IGBT (T1L) 8 Temperature sensor
NOTE
IGBT stands for Insulated Gate Bipolar Transistor.
1-3
MAIN CONTROLLER
Logic Card Components
Odd number pins on tops.

Even number pins on bottom.
206797
1 Selector switches (SW1 to SW8) 4 CN2 connector (Pin Nos. 23 to 38)

2 Microprocessor (MPU) 5 CN3 connector (Pin Nos. 39 to 64)
3 CN1 connector (Pin Nos. 1 to 22)
1-4
MAIN CONTROLLER
Controller Models
(1) The following controller model is used on this lift

truck.
Voltage Hydraulic control Remarks

48 V Chopper Maximum drive motor current: 250 A.
(2) The DSWs of the logic card are set according to

vehicle weight (1.6, 1.8 and 2.0 tons). The maximum
vehicle speed varies depending on load weight, as
shown in the table below.
Truck Models 1 ton class 2 ton class

Travel Speeds
48 V km/h (mph) 16/14 (10/8.7) 16/14 (10/8.7)
Unloaded/Loaded
1-5
MAIN CONTROLLER
Operation Outline Drive System
(1) Power ON, default condition Neutral Position

• Turning on the key switch supplies power to the When the direction lever is in the neutral position, the
logic card and display unit. The display unit controller turns the regeneration contactor OFF and
shows three hourmeters in sequence, then cuts off the current to the armature. When the lever is
resumes the normal display mode. moved to the neutral position while the vehicle is
moving, the vehicle continues traveling due to inertia.
• About one second after power is supplied to the
When the lever is shifted to neutral from forward or
logic card, the controller turns the line contactor
reverse position, the controller maintains the neutral
ON to provide power to the main circuit. When
mode for five seconds, and the regeneration contactor
the line contactor turns ON, the steering motor
stays ON.
starts rotating.
• By setting the DRS switch to D or S, it is
possible to activate the self-diagnostic function, Powering
set vehicle characteristic parameters with setup (1) Outline
options and perform an analysis of malfunction • Powering is a condition in which the motors are
data. Remove the main fuse. powered by the battery and the controller
(2) Normal mode (RUN mode) supplies a current determined by the powering
characteristic. The powering characteristic is an
• When the direction lever is engaged and the
electric current curve relative to vehicle speed
accelerator pedal is pressed, the vehicle moves
based on the acceleration parameter, as shown in
forward or backward. During deceleration, the
the diagram. The current demand value is
motors conduct various regenerative operations
obtained from the acceleration and vehicle
according to the settings.
speed.
• Moving the hydraulic lever activates the pump
• The power characteristic can be selected from
motor and provides hydraulic power.
three types by SUO #9: Economy, Standard and
• The controller monitors operating conditions. High Power.
When an abnormality occurs, the display unit
• The current demand rise rate is selectable.
indicates an error code and activates an
(Acceleration rate: SUO #8)
appropriate fail-safe function. The error code is
stored in the logic card memory. (2) Truck mode
• The truck mode can be selected from A to E,
each with preset values for maximum vehicle
speed, acceleration rate, power, automatic
regeneration power, start lift speed, top lift speed
and tilt speed.
• SUO #1 is used for setting the truck mode.
Details are shown on page 1-8.
• When the truck mode is set, the values shown in
the table are entered in the applicable set option
items. When default settings are changed, the
indication (A to E) flashes to indicate that the
settings are modified.
• If the truck is set in high power mode, the
battery life will be less than economy and
standard mode.
1-6
MAIN CONTROLLER
Drive Motor’s Current Table

Armature Current Table
High power mode

Standard mode
Economy mode
Thermal & Battery [0] mode
Brake Limit mode
207520
Shunt Current Table
High power & Standard & Economy mode
Thermal & Battery [0] mode
Brake Limit mode
207521
1-7
MAIN CONTROLLER
• Mode setting
Setting Application Function Default value

Start Start
Accel- Accel- Top Auto
Speed Power Lift Tilt Regen Speed Power lift lift Tilt
eration eration lift regen
(MC) (FC)
A Normal M M Std. M M M 14 2 2 7 5 9 6 3
High
b performance F F Power. F M M 16 3 3 7 5 10 6 3
C Economy S S Eco. S M M 12 1 1 6 4 8 6 3
d Long travel F M Power. M M M 16 2 3 7 5 9 6 3
E Short shuttle S F Eco. F M M 12 3 2 7 5 10 6 3
SUO # 7 8 9 2 2 3 4 23
M: Medium F: Fast S: Slow

SUO: Setup options
1-8
MAIN CONTROLLER
Regeneration (3) Regeneration mode priority

When the lever regeneration function and one of
(1) Lever regeneration the above two regeneration modes demand different
When the direction lever is shifted into the position amounts of regeneration, the amount requested by
opposite to the vehicle’s traveling direction, the the lever regeneration function takes precedence.
regeneration function is activated. The amount of
(4) Regenerative behavior when vehicle movement
regeneration is determined by the lever
is opposite to transmission position
regeneration characteristic, as shown in the
diagram. The regeneration characteristic curve is When the vehicle is moving in the direction
selected by SUO #22. The degree of acceleration opposite to the transmission position such as on a
serves as the parameter. The harder the accelerator slope, the regeneration function is activated at a
pedal is pressed, the higher the amount of vehicle speed of 2 km/h (1.24 mph) or higher.
regeneration becomes.
The lever regeneration function is always operative
regardless of the following regeneration mode.
(2) Regeneration modes

• One of the following two regeneration modes
can be selected with SUO #21.
(a) Mode 1: Brake regeneration with accelerator
priority
The regeneration function is activated when
the brake is applied. When the accelerator
pedal is depressed, however, the regeneration
function becomes inactive.
When the accelerator and brake pedals are
operated simultaneously, the drive system
provides driving power.
• The amount of regeneration is determined
by the lever regeneration characteristic
selected by SUO #22 (see pages 1-10 and 1-
20).
(b) Mode 2: Accelerator regeneration
The regeneration function is activated when
the accelerator pedal is released.
• The amount of regeneration is determined
by the automatic regeneration characteristic
selected by SUO #23 (see pages 1-11 and 1-
20).
When the vehicle speed is 1 km/h (0.62 mph)
or slower, the regeneration function is
inactive.
1-9
MAIN CONTROLLER
Lever Regeneration Characteristic

Range 5
Range 1
207524
Shunt Current Table
Range 3 & 4 & 5
Range 1 & 2
207525
1-10
MAIN CONTROLLER
Auto Regeneration Characteristic

Range 5
Range 1
207528
Shunt Current Table
Range 5
Range 1 & 2 & 3
207529
1-11
MAIN CONTROLLER
Hydraulic System (4) Priority

When two or more levers are operated at the same
Manual Control Model time, the following priority order is effective.
The hydraulic levers are used to operate the pump (High priority) Tilt lever, Attachment 1 lever,
motor. The fixed duties selected by the setup options Attachment 2 lever.
below provide chopper control for the IGBTs. (Low priority) Lift
(1) Start lift speed (SUO #2) and top lift speed (SUO
#3) Finger-tip Control Model
The two-stage lift lever is used to set the speed.
This model is equipped with a finger-tip control device.
The first stage is for the start lift speed, and the
Finger-tip control levers are used instead of manual
second stage is for the top lift speed. Do not set the
levers. The FC controller outputs encoded 5-step speed
start lift speed faster than the top lift speed.
instructions and error signals to provide chopper
(2) Tilt speed (SUO #4) control for the IGBTs.
The tilt lever is used to set the speed.
(3) Attachment 1 speed (SUO #5) and attachment 2
speed (SUO #6)
The attachment levers are used to set the speed.
FC controller signal
Lever operation and error data Hydraulic speed
CN1-20 CN1-19 CN1-18 CN1-17 CN1-16
0 0 0 0 0 No operation. Duty 5% fix.
0 0 0 0 1 1st-stage lift operation. SUO # 2
0 0 0 1 0 2nd-stage lift operation. SUO # 3
0 0 0 1 1 Tilt operation. SUO # 4
0 0 1 0 0 Attachment 1 or attachment 2 operation. SUO # 5
0 0 1 0 1 Lift down. Duty 10% fix.
0 1 * * * Finger control lever abnormality.
1 0 * * * Solenoid abnormality.
1 1 * * * Hydraulic sensor abnormality.
0 0 1 1 0 Not all levers in neutral or OFF position at power ON.

0 1 1 1 0 Lift and tilt levers in ON position at power ON.
1 0 1 1 0 Lift, tilt and attachment levers in ON position at power ON.
0 0 1 1 1 Seat switch OFF at power ON.

1 1 1 1 1 FC controller abnormality
***: Except 110 and 111

1: Open (15V) 0: Close (0V)
1-12
MAIN CONTROLLER
Fail-Safe System Simultaneous operations — Cargo handling

operations cannot be conducted unless the vehicle
Output Power Control at Low Battery is stationary and the direction lever is in the neutral
Voltage position.
(b) When the battery voltage momentary becomes
(1) Battery discharge characteristic higher than 22 V and less than 25 V, the
The BDI table shows the BDI indicator patterns on following limit control is activated. When this
the display and the corresponding voltage ranges. happens, the Battery LED on the display
flashes.
Drive motors — The output power is controlled
BDI Table
according to the powering characteristic.
BDI # Normal BDI Tubular BDI
• In the 48-V vehicle, the brake limit mode is
0 - 45.9 - 46.9 activated.
1 46.0 - 46.4 47.0 - 47.3 (Brake limit mode: Drive motor power is
2 46.5 - 46.9 47.4 - 47.7 controlled while the brake pedal is depressed.
3 47.0 - 47.4 47.8 - 48.1 See page 1-7.)
4 47.5 - 47.9 48.2 - 48.5 Pump motor — No output limit control is provided.
5 48.0 - 48.4 48.6 - 48.9 (c) When the battery voltage momentary becomes
lower than 22 V, the line contactor turns OFF.
6 48.5 - 48.9 49.0 - 49.2
When this happens, the Battery LED on the
7 49.0 - 49.3 49.3 - 49.5 display lights and the “Lo” indicator flashes.
8 49.4 - 49.7 49.6 - 49.8
9 49.8 - 50.1 49.9 - 50.1
10 50.2 - 50.2 -
(2) Output power control

When the BDI indicator shows zero, the following
output power control is activated.
(3) Output limit control

(a) When the BDI display shows zero level, the
following limit control is activated. When this
happens, the Battery LED on the display
lights.
Drive motors — The output power is controlled
according to the powering characteristic. See page
1-7.
Pump motor — In the MC and FC models, the
output duty is reduced by 50% during lifting and
attachment operations.
Tilt operations do not change the output duty.
1-13
MAIN CONTROLLER
Overheat Chat Timer (SUO #24)

(1) Drive motor overheat (Error codes E0, E1) • When the following conditions remain for the time
duration set by SUO #24, the line contactor turns
The output limit control is provided only for the
OFF.
drive motors due to the thermal mode of the
powering characteristic. See page 1-7. Acceleration: 0
Direction lever: Neutral
(2) Pump motor overheat (Error code E2)
Lift, tilt and attachment levers: OFF
In the cargo chopper model, the output duty is
reduced by 50% during lifting and attachments Steering: Not operated
operations. • Operating any of the above resets the line contactor.
(3) Controller overheat (Error code E3)

The output limit control is provided only for the Seat Switch Timer (SUO #25)
drive motors due to the thermal mode. See page 1-7. • When the operator leaves the seat for the time
duration set by SUO #25, the line contactor turns
OFF. When the power switch is turned on without
reduced by 50% during lifting and attachments
the operator sitting on the seat, the line contactor
operations.
turns OFF and the “E” indication flashes on the
display unit.
Brush Wear • With acceleration at 0, direction lever in neutral and
(1) Drive motor brush wear (Error codes E4, E5) hydraulic levers OFF, turning on the seat switch
resets the line contactor.
The output limit control is provided only for the
drive motors due to the brush mode. See page 1-7.
(2) Pump motor brush wear (Error code E6)

Malfunction Detection
(Run Time Diagnosis)
reduced by 50% during lifting and attachments
If a malfunction is detected, the LED flashes and the
operations.
error code is indicated on the display unit. The
corresponding fail-safe function is also activated at the
Maximum Vehicle Speed Control (SUO same time. Refer to the malfunction detection and
#7) main circuit errors table.
The setup option setting limits the maximum vehicle
speed.
Output Power Control During Braking

The maximum current is controlled when the service
brake or parking brake is applied.
(1) Service brake — Maximum shunt current: 15 A,
maximum armature current: 125 A
(2) Parking brake — Maximum shunt current: 15 A,
maximum armature current: 125 A
1-14
MAIN CONTROLLER
Malfunction Data Record Setting

(History Folder)
Printed Circuit Board Settings
Data Storage Refer to the printed circuit board adjustment and setting
Errors are automatically stored in the logic card items table. See page 1-23.
memory. Stored data includes the following
information.
Adjustment of Remaining Battery
• Error code Level
• Battery discharge level at the time of error • Set the DRS switch to R.
generation • Set DSW 1 on the logic card to ON.
• Vehicle hourmeter reading at the time of error • Turn the key switch on.
generation
• Measure voltage between the POS and NEG
A maximum of 32 sets of data can be stored. If this terminals of the controller assembly with a
capacity is exceeded, the oldest data will be erased to multimeter. Adjust the trimmer potential adjuster so
accommodate new data. the measured value corresponds to the indication on
the display.
Review of Stored Data • When the voltage matches, turn the key switch off.
(1) To review data • Set DSW 1 on the logic card to OFF.
• Set the DRS switch to D.
• Set the seat switch to OFF. If the seat switch is
set to ON, a “dd” will be displayed.
• With the lift and tilt levers pulled back, turn on
the key switch.
• The display unit shows the above mentioned
data (three types of information). To display
previous data, set the DRS switch to R then to
D. When there is no data to display, a “done”
indication appears. The display does not repeat
showing data from the beginning.
R
S D
Pull
211196
206794
(2) To delete data

• Operate the DRS switch until the display shows
“done.”
• With “done” on the display, keep the DRS
switch at S for more than one second, then
return the DRS switch to R. This deletes all data
in the memory, then the “done" indication on the
display flashes.
1-15
MAIN CONTROLLER
Setup Options (4) To set default values

For details, refer to the setup options table. The following procedure sets default values in the
setup option values. After the logic card is
(1) To enter setup option mode.
replaced, be sure to perform this setting first.
Group 1: Set the DRS switch to S, set the seat
• Set the DRS switch to S.
switch to OFF, and turn on the key
switch. The display shows “01.” • Set the seat switch to OFF.
Group 2: Set the DRS switch to S, set the seat • Shift the direction lever to R, hold the
switch to OFF, and turn on the key accelerator pedal pressed, then turn the key
switch while keeping the lift and tilt switch on. The display indicates “done.”
levers pulled back. The display shows • Set the DRS switch to R.
“11.”
(2) To select option # and set data Self-diagnosis

• The option # is indicated on the speed indicator
on the display unit, and the data is shown on the Check the input and output status. For details, refer to
hourmeter. the self-diagnosis table.
• To select option #, set the DRS switch to R and Set the DRS switch to D, and turn on the key switch to
then to S. enter the self-diagnosis mode. To conduct a diagnosis,
set the switch to R then to D. Be sure to remove the
• To set data, use the direction lever. To increase
line fuse (500 A) before conducting a diagnosis.
the value, move the lever to F. To decrease the
value, move the lever to R. • The table below shows the conditions under which
the controller can enter a certain mode. When the
(3) To register data DRS switch and other conditions are set according to
• Setting the DRS switch to R and S registers the the table and the key switch is turned on, the
data. When the DRS switch is set to R, the data corresponding mode listed in the left column is
is written, and the display indicates triple bars. activated. To exit from the selected mode, turn the
When the last item is entered, the display key switch off.
indicates “done.”
211432
Mode DRS switch position Other condition

Self-diagnosis D
Set seat switch to OFF and pull both lift and tilt
Malfunction data save D
levers.
Setup option group 1 S
Set seat switch to OFF and pull both lift and tilt
Setup option group 2 S
levers.
Set seat switch to OFF, shift direction lever
Setup option default setting S
to R and press accelerator pedal.
1-16
MAIN CONTROLLER
Other Functions Display Unit
(1) Service indicator (SUO #10) BDI (Battery Discharge Indicator)

When the vehicle hourmeter indication reaches the • The battery discharge level is indicated by the 10-
set value, the service indicator turns ON to notify segment LCD. This indication is based on the BDI
the need for maintenance. Output power control characteristic. When the BDI shows only one
can be also activated at the same time. The setting segment, the LED starts flashing to notify the low
can be made in a range of 100 to 500 at 50 hour battery power level. When the BDI indication
increments. The service indicator turns ON when disappears, the LED remains lit and the output
the hourmeter indication exceeds the value of the control is activated.
current hourmeter reading plus the set value. • The BDI turns OFF when not necessary, such as
The indicator starts flashing 20 hours before the set during setup option setting and self-diagnosis
time, and remains lit when the hourmeter indication operation.
reaches the set time.
Setting “0.1” activates the demo mode. In this
mode, the output power control is conducted six
minutes after the setting is made.
(2) Auxiliary input for function control

(SUO #11-#19)
Auxiliary inputs to the logic card can be used to
limit the maximum vehicle speed, prohibit lift and
reduce output power.
208114
The vehicle speed setting by auxiliary input has
precedence over the maximum vehicle speed set by
SUO #7.
Hourmeters and Time Display
(3) Speed alarm (SUO #26)
When the vehicle reaches the set speed, an alarm (1) Normal operation
signal (logic card hardware output signal) is • When the key switch is turned on, the
generated. hourmeters for the vehicle, drive motors and
pump motor are indicated in sequence. The
(4) Tire size adjustment (SUO #27)
hourmeters for the motors show cumulative
This function provides a correction value to operating hours, and the vehicle hourmeter
compensate for a diameter change resulting from indicates cumulative line contactor ON hours.
tire wear. It is used to adjust the vehicle speed
• A clock display is shown under normal
data.
condition.
(2) During setup option setting and self-diagnosis

operation
• The hourmeters are not displayed when the key
switch is turned on.
• Data are indicated on the display.
1-17
MAIN CONTROLLER
Vehicle Speed and Error Code Display (7) Malfunction lamp

The indicator flashes when a malfunction is
• The display indicates vehicle speed under normal
detected. Refer to the malfunction detection table.
condition, and shows an error code when an
abnormality occurs. (8) Speedometer/Error indicator
• The display shows item number during setup option Indicates speed of the truck. Or, error conditions.
setting and self-diagnosis operation.
Action Lights (LEDs)

The indicators are activated when an error is detected
during normal condition. They do not turn on during
setup option setting or self-diagnosis operation.
(1) Service indicator (SUO #10)

The indicator starts flashing 20 hours before
maintenance is required and remains lit when the
set time is reached.
(2) Motor brush

The indicator turns ON when the motor brush
needs to be replaced.
(3) Thermal
The indicator turns ON when a motor or the
controller overheats.
(4) Battery
• The indicator flashes when the BDI has one
indicator segment, and stays lit when the BDI
has no segment.
• The indicator flashes when the battery voltage
momentarily becomes higher than 22 V and
lower than 25 V. The indicator turns off when
the voltage exceeds 25 V.
• The indicator lights when the battery voltage
momentarily becomes lower than 22 V.
Once all the indicator segments of the BDI turn
off, the output limit control function does not
cancel until the battery is recharged and five or
more indicator segments light.
(5) Brake fluid

The indicator flashes when the brake fluid level
becomes low.
(6) Parking brake

The indicator flashes when the parking brake is
engaged.
1-18
MAIN CONTROLLER
Setup Options (Group 1)

Default Value
Option
Title of Option Description Range 48 V type
#
MC type FC type
A, B, C, D, E
There are 5 truck modes and each has 7 If any of these
Application option values: options values are
#1 Pre-Sets Top travel speed, Acceleration rate, changed, A through E A A
(Truck Operation Traveling power, Regen adjustment, Start will flash in order to
Mode) lift speed, Top lift speed, Tilt speed. show that the truck
For details, see page 1-8. mode is not in
default setting.
Lift speed when first lift switch is on.
#2 Start Lift Speed Start lift speed cannot exceed Top lift speed. 1 to 10 7 5
Maximum lift speed when second lift 1 to 10 9 9
#3 Top Lift Speed switch is on.
Tilt speed is prior to Lift speed in case that 2 to 8 6 6
#4 Tilt Speed the two levers are simultaneously operated.
Speed setting for attachment 1
#5 Auxiliary 1 Speed (1: SLOW → 10: FAST) 1 to 10 3 3
Speed setting for attachment 2
#6 Auxiliary 2 Speed (1: SLOW →10: FAST) 1 to 10 1 1
#7 Top Travel Speed Maximum travel speed 48 V type: 5 to16 km/h 14 14

Limit
#8 Acceleration Rate Choice of acceleration rate 1,2,3 2 2

(1: SLOW, 2: MIDDLE, 3: FAST)
Choice of powering characteristic
#9 Traveling Power (1: ECONOMY, 2: STANDARD, 1,2,3 2 2
3: POWERFUL)
This option sets the time which indicates
the maintenance time for the operator. The
amount of time set by this operation is
added to the truck’s hourmeter at that time 100 to 500 hours in
and the total value is stored in memory as 50-hr. increments.
the “maintenance time.” When the truck’s Attached “=” to the
#10 Service Indicator hourmeter reaches the maintenance value, the power 0 0
time, the service indicator LED will turn on. reduction function
It will flash 20 hours before maintenance will be effective.
time. You can reduce the truck power when Selecting 0.1 makes
the LED is solid on, by selection. You can the truck demo-
also set the demo-mode, which shows the mode.
Service Indicator function quickly. (6 min
after setting 0.1)
NOTE
(1) The service indicator shows the set value, not the current value. If the key switch is turned off without
entering data (without setting the switch to R), the current value is maintained. When data is entered, the
current value is replaced by the setting value on the display.
(2) The output power control function of the service indicator is the same as the output power control that is
activated when the battery voltage level drops.
(3) When the truck mode is selected, all data is replaced by the set values of the selected mode. When the set
values are changed, the truck mode indicator (A to E) flashes to notify that the settings are modified.
1-19
MAIN CONTROLLER
Setup Options (Group 2)

Option Default
Title of Option Description Range
# value
When the auxiliary input signal is 0: Turned off
on, the controller will limit top speed 1: Disable lift (input; low volts)
Auxiliary Input for or inhibit lifting or reduce power 2: Speed limit (input; low volts)
#11 Lift and Drive according to the selection. The speed 3: Power reduction (input; low volts) 0
Speed 1 limit set by this operation is prior to 4: Disable lift (input; high volts)
#7 top travel speed limit. 5: Speed limit (input; high volts)
6: Power reduction (input; high volts)
Auxiliary Travel
#12 Speed Limit 1 Travel speed limit for #11 48 V type: 5 to 16 km/h 10
#13 Auxiliary Power Power reduction ratio for #11 0 to 99% 0

Reduction 1
Auxiliary Input for
#14 Lift and Drive Same as #11 Same as #11 0
Speed 2
Auxiliary Travel
#15 Speed Limit 2 Travel speed limit for #14 48 V type: 5 to 16 km/h 10

Reduction 2
Auxiliary Input for
#17 Lift and Drive Same as #11 Same as #11 0
Speed 3
#18 Auxiliary Travel Travel speed limit for #17 48 V type: 5 to 16 km/h 10
Speed Limit 3
Reduction 3
If a drive motor stalls for the amount
#20 Stall Timer time set by this option, the motor 2 to 10 sec 5
current gets to 0.
1: Brake regen (accelerator must be
#21 Regen Function 2 regen modes off) 2
2: Accelerator regen (also called
“auto reg”)
Regen Adjustment
#22 for Lever Reg 5 characteristic curves of lever regen 1 to 5 4
Regen Adjustment
#23 for Auto Reg 5 characteristic curves of auto regen 1 to 5 3
#24 Chat Timer Sets the amount time before the truck 0 to 40 sec 20
enters chat mode.
If the operator leaves the seat for the
#25 Seat Switch Timer amount of time set by this option, 3 to 15 sec 5
the line contactor will turn off.
If the truck reaches the speed set by
#26 Speed Alarm this option, the controller outputs a 48 V type: 5 to 16 km/h 12
speed alarm signal.
Tire Size Adjusts the tire diameter. It changes
#27 Adjustment the truck’s speed recognition and the 0 to 40 20
speedometer.
1-20
MAIN CONTROLLER
Setup options #11 through #19 are maximum speed

limit, power reduction or disable lift settings.
The speed limitation is triggered from a specific switch

input occurrence.
Multiple input signals are available in order to establish
a speed limit for each signal.
Feature of maximum speed limit

Item Description SUO No. Harness Pin No.
Auxiliary travel speed limit 1 Effective when aux. input 1 close/open #11, 12 CN2-23
Miscellaneous features for drive

Auxiliary power reduction 1 Effective when aux. input 1 close/open #11, 13 CN2-23
Feature of disable lift

Auxiliary input for lift 1 Stops lift when aux. input 1 close/open #11 CN2-23
1-21
MAIN CONTROLLER
Self-diagnosis
Step Checking Do this Controller check this Result Display Motion
0 Power line Turn on key Close line contactor and Pass 01 Line contactor closes
voltage switch. check power line voltage. and opens.
(fuse check) Fail dd
1 Seat switch Release and press and Input OFF→ON→OFF Pass 02
release seat switch. Fail 01
2 Direction Cycle direction lever: Input change as Pass 03
switch N→R→N→F→N. N→R→N→F→N Fail 02
3 Parking brake Release and depress and Input OFF→ON→OFF Pass 04
release parking brake. Fail 03
4 Service brake Depress and release Input OFF→ON→OFF Pass 05
service brake. Fail 04
5 Accelerator Depress accelerator Pass Number 0 to 15 flickers as
and release. accelerator is depressed.
Fail ----
DIAG→RUN ---- 06
6 Battery voltage (Automatic) Check battery voltage: Pass 07
RUN→DIAG 36/48 V Fail 06
7 Lift switch Pull and release Chopper: Pass 08
lift lever. Check 2-stage switch input.
(OFF→SW1/ON→SW2/ON
→SW2/OFF→SW1/OFF)
Contactor: Fail 07
Check switch input.
(OFF→ON→ON)
8 Tilt switch Pull and release Input OFF→ON→OFF Pass 09
tilt lever. Fail 08
❋
9 Attachment Pull and return Input OFF→ON→OFF Pass 10
1 switch attachment 1 lever. Fail 09
(DIAG→RUN→DIAG)*
❋
10 Attachment Pull and return Input OFF→ON→OFF Pass 11
2 switch attachment 2 lever. Fail 10
(DIAG→RUN)*
RUN→DIAG ---- 00
11 Hydraulic pump Pull any lever and see Pass Flickering pump speed value
speed check display. Fail Other than above
DIAG→RUN ---- 12
12 Line contactor RUN→DIAG and see Pass 12 Contactor closes.
line contactor. Fail 12 No operation
DIAG→RUN and see Pass 13 Contactor opens.
line contactor. Fail 12 No operation
13 Regeneration RUN→DIAG and see Pass 13 Contactor closes.
contactor regeneration contactor. Fail 13 No operation
DIAG→RUN and see Pass 14 Contactor opens.
regeneration contactor. Fail 13 No operation
14 ----------- RUN→DIAG →RUN ---- done
❋
In case of no Attachment 1 (2) switch, skip to next step by operating DRS switch.
1-22
MAIN CONTROLLER
Logic Card Adjustment / Setting
Adjustment
No. Item Description How to set Contents
part
Turn on key set with
DSW 1 on. Turn the
Battery voltage Adjust the voltage on the trimmer until the voltage DSW 1
1 adjustment logic card to equal the actual shown on the display trimmer
battery voltage. equals the voltage meas-
ured by the multimeter.
DSW 2 on, DSW 3 on: 2.0 ton
Choice of 1.6/1.8/2.0 ton class. DSW 2 off, DSW 3 on: 1.8 ton
2 Truck model Error 65 will occur if DSW is Set DSW DSW 2,3 DSW 2 on, DSW 3 off: 1.6 ton
not set. DSW 2 off, DSW 3 off: error
Tubular BDI For the battery which has a on: Tubular BDI option
3 option different BDI discharge curve. Set DSW DSW 7 off: Normal battery
on: FC control
4 FC control option For FC control Set DSW DSW 8 off: MC control
Choice of truck Choice of 3-wheel or 4-wheel on: 3-wheel truck
5 Set DSW DSW 4
model truck (48V chopper type only) off: 4-wheel truck
Choice of on: Foot direction
6 Choice of lever or foot direction Set DSW DSW 5
direction off: Direction lever
7 — — — DSW 6 Spare (Normally “off”)
Example of setting:
1 2 3 4 5 6 7 8
EP20KC (4-wheel)
FC model
Normal battery
Direction lever
OFF
Selector switches (SW1)
211444
1-23
MAIN CONTROLLER
Run Time Diagnostics
Display
LED Code
To return
Steering operation
Fault How to detect Result to normal
Brake Fluid
Brush Wear
Over Temp
Park Brake
Service
Battery
Error
Over temperature R-motor Thermal contact (150ºC) * E0 Power reduction Cool
Over temperature L-motor Thermal contact (150ºC) * E1 Power reduction Cool
Over temperature P-motor Thermal contact (150ºC) * E2 Power reduction Cool
Over temperature controller Thermistor (80ºC) * E3 Power reduction Cool
Brush wear R-motor Brush wear sensor * E4 Power reduction Turn key off
Brush wear L-motor Brush wear sensor * E5 Power reduction Turn key off
Brush wear P-motor Brush wear sensor * E6 Power reduction Turn key off
Brake fluid low level Level sensor (Contact) * Turn key off
Armature fault R Checks voltage and current of power circuit. * 10 3 Line contactor off Turn key off
IGBT breaking R Checks voltage and current of power circuit. * 11 3 Line contactor off Turn key off
IGBT short R Checks voltage and current of power circuit. * 12 3 Line contactor off (✩) Turn key off
IGBT driver fault R Fault signal from the drive board * 13 3 Line contactor off (✩) Turn key off
Current sensor fault R Checks the current sensor output. * 14 3 Line contactor off Turn key off
Armature overcurrent R more than 350 A * 15 3 Line contactor off (✩) Turn key off
Stall timer R Measures the time (set by SUO#20) while stalling. * 16 3 Line contactor off Turn key off
Field fault R Checks voltage and current of power circuit. * 17 3 Line contactor off Turn key off
Field driver fault R Fault signal from the H-bridge board * 18 3 Line contactor off (✩) Turn key off
Field overcurrent R more than 45 A * 19 3 Line contactor off (✩) Turn key off
Armature fault L Checks voltage and current of power circuit. * 20 3 Line contactor off Turn key off
IGBT breaking L Checks voltage and current of power circuit. * 21 3 Line contactor off Turn key off
IGBT short L Checks voltage and current of power circuit. * 22 3 Line contactor off (✩) Turn key off
IGBT driver fault L Fault signal from the drive board * 23 3 Line contactor off (✩) Turn key off
Current sensor fault L Checks the current sensor output. * 24 3 Line contactor off Turn key off
Armature overcurrent L more than 350A * 25 3 Line contactor off (✩) Turn key off
Stall timer L Measures the time (set by SUO#20) while stalling. * 26 3 Line contactor off Turn key off
Field fault L Checks voltage and current of power circuit. * 27 3 Line contactor off Turn key off
Field driver fault L Fault signal from the H-bridge board * 28 3 Line contactor off (✩) Turn key off
Field overcurrent L more than 45 A * 29 3 Line contactor off (✩) Turn key off
Armature fault P Checks voltage and current of power circuit. * 30 3 Line contactor off Turn key off
IGBT breaking P Checks voltage and current of power circuit. * 31 3 Line contactor off Turn key off
IGBT short P Checks voltage and current of power circuit. * 32 3 Line contactor off (✩) Turn key off
Field driver fault P Fault signal from the driver board * 33 3 Line contactor off Turn key off
Current sensor fault P Checks the current sensor output. * 34 3 Line contactor off Turn key off
Overcurrent P more than 450 A * 35 3 Line contactor off (✩) Turn key off
Line contactor fault Checks voltage and current of power circuit. * 40 3 Line contactor off Turn key off
Regen contactor fault Checks voltage and current of power circuit. * 41 3 Line contactor off Turn key off
Pump contactor fault Checks voltage and current of power circuit. * 42 3 Line contactor off Turn key off
Regen diode fault Checks voltage and current of power circuit. * 43 3 Line contactor off Turn key off
Armature diode fault R Checks voltage and current of power circuit. * 44 3 Line contactor off Turn key off
1-24
MAIN CONTROLLER
Armature diode fault L Checks voltage and current of power circuit. * 45 3 Line contactor off Turn key off
Armature diode fault P Checks voltage and current of power circuit. * 46 3 Line contactor off Turn key off
Armature breaking R Checks voltage and current of power circuit. * 47 3 Line contactor off Turn key off
Armature breaking L Checks voltage and current of power circuit. * 48 3 Line contactor off Turn key off
Armature breaking P Checks voltage and current of power circuit. * 49 3 Line contactor off Turn key off
Accelerator sensor fault Out of normal range * 51 3 Line contactor off Turn key off
Speed sensor fault R Checks breaking and short. * 52 3 Line contactor off Turn key off
Speed sensor fault L Checks breaking and short. * 53 3 Line contactor off Turn key off
FC lever fault Fault signal from FC controller * 54 Disable the lever op. Turn key off
FC solenoid fault Fault signal from FC controller * 55 Disable the solenoid Turn key off
FC controller fault Fault signal from FC controller * 57 3 Line contactor off Turn key off
Steering sensor abnormality Signal input when power is turned on * 80 3 Line contactor off Turn key off
Dirct. lever / accel not neutral The lever / accel is not neutral at power-on. E 3 Line contactor off Place to neutral
Seat switch not on The switch is off at power-on. (E) 3 Line contactor off Switch on
Lift lever not neutral The lever is not neutral at power-on. H1 3 Line contactor off Place to neutral
Tilt lever not neutral The lever is not neutral at power-on. H2 3 Line contactor off Place to neutral
Aux1 lever not neutral The lever is not neutral at power-on. H3 3 Line contactor off Place to neutral
Aux2 lever not neutral The lever is not neutral at power-on. H4 3 Line contactor off Place to neutral
FC controller lever not neutral The lever is not neutral at power-on. H5 Disable the lever op. Place to neutral
Serial communication fault When serial communication is not going on * 60 3 Line contactor off Turn key off
EEPROM fault Parity check of SUO data * 61 3 Line contactor off Turn key off
Logic card not initialized DSW is not set. * 65 3 Line contactor off Turn key off
Logic card fault Sum check of ROM & RAM * 66 3 Line contactor off Turn key off
Battery voltage too low Voltage class is not correct (lower than 42 V). * 68 3 Line contactor off Turn key off
Battery voltage low Voltage class is between 22 V to 25 V. (*) Power reduction At recovery voltage
Battery voltage low Voltage class is lower than 22 V. * (Lo) 3 Line contactor off Turn key off
NOTE
(1) E0 to E6 do not appear on the display, but are stored in the history folder.
(2) E, (E), H1 to H5, 60 and Lo appear on the display, but not stored in the history folder.
(3) (*), (E) and (Lo) means flashing. “ ” means that the steering operation is operable and “3” means that it is
inoperable.
(4) “Line contactor off (✩)” means that the contactor will open immediately after a fault is detected.
“Line contactor off” means that the contactor will open after the current goes to 0.
1-25
MAIN CONTROLLER
Inspection and Adjustment
Inspection and Adjustment Tools (b)
(a) Multimeter
(b) Clamp meter (a)
(c) IC clip
(d) Dial adjustment screwdriver (precision
screwdriver)
(c)
NOTE
The illustration shows a digital multimeter. With this
(d)
tester, the positive (+) terminal is applied with positive 206385
charge, and the negative (–) terminal with negative
charge. It should be noted that the terminals must be
connected inversely when using an analog meter tester.
! WARNING
Disconnect the battery plug before inspecting or
adjusting the controller.
Removal and Installation of Logic Card
! WARNING
Disconnect the battery plug before approaching
the controller.
(1) Removal of rear cover

(a) Turn the key switch off.
(b) Disconnect the battery plug.
(c) Remove the rear cover of the counterweight.
(2) Removal of logic card cover

Remove the cover mounting screws (four places), and
remove the logic card cover.
206979
1-26
MAIN CONTROLLER
(3) Removal of logic card

(a) Disconnect controller harness connectors CN1,
CN2 and CN3, and harness B connectors CN1,
CN2 and CN3. CN3
Controller
harness CN2
NOTE connector
CN1
Grip the connectors to unplug. Do not pull the
harnesses to disconnect the connectors.
CN3 CN2 CN1

(b) Remove the screws (five places) that mount the
logic card to the control panel.
Harness B
(c) Remove the logic card. 211434
(4) Installation
Follow the removal procedure in reverse.
Tightening of High-tension Cable

Terminals
! CAUTION
Be sure to regularly check the tightened torque of the high-tension battery cable terminals. If the
cables are loosely connected, excessive contact resistance results, and it can cause overheating and
lead to a fire in the worst case. When checking or adjusting the cable routing, avoid pulling the cables.
If the cables move even slightly at the terminals while working with the cables, be sure to tighten the
terminal connections.
• Stud terminals
7 stud terminals (indicated by arrows in the diagram on
page 1-28.): Tightening torque (See table below.)
11.77 ± 1.96 N·m (1.2 ± 0.2 kgf·m) [8.68 ± 1.45 lbf·ft]
Stud size: M8
Width across nut flats: 12 mm (0.47 in.)
Be sure to mount
the disc spring as shown
(a) Note that a flat washer and a disc spring are
Busbar
installed on each connector terminal.
Flat washer (large)
(See illustration at right.)
Disc spring
(b) The stud terminal sections have resin parts. When (small)
tightening the nut, hold the resin parts with a
Observe
wrench [17 mm (0.67 in.) size]. (See following installation
diagram.) order and
orientation
206246
1-27
MAIN CONTROLLER
Stud terminal section

Resin part (black)
206796A
Component Testing
! CAUTION
(a) Use compressed air to clean the controller.
Using steam or a solvent for cleaning can
damage parts.
(b) For cleaning, use an air compressor equipped
with a moisture-removing filter. Do not set the
air pressure above 196 kPa (2 kgf/cm 2) [28
psi].
(c) When connecting the battery plug for the first
time after maintenance work, check to make
sure that resistance between the positive (+)
and negative (–) battery terminals on the
vehicle side is 10 kΩ or higher.
NOTE
When installing wires and cables, be sure to tie them
together at the bus bar.
1-28
MAIN CONTROLLER
(1) Measurement of logic card voltage
! WARNING
The lift truck can move suddenly. Injury to
personnel or damage to the lift truck is possible.
Safely lift the drive wheels off the floor. Put blocks
of wood under the frame so that both drive wheels
are free to turn.

(c) Remove the cover of the logic card.
(d) Reconnect the battery plug.
(e) Turn the key switch on. Connect the negative (–)
terminal of the multimeter to the NEG terminal of the
control panel.
(f) Set the multimeter to the 50- or 100-VDC range.
(g) Connect the positive (+) terminal of the multimeter to
each pin of connectors CN1, CN2 and CN3 using the
IC clip, and measure voltage.
NOTE
Be careful not to short-circuit pins.
For the normal voltage value, refer to the logic card
voltage chart on the following page.
IC clip
CN1
CN2
NEG terminal
206977A
1-29
MAIN CONTROLLER
Logic Voltage Checks CN1

Logic Wire No. Function Normal Activated Test Procedures
Terminal MC (FC) Voltage Voltage
(CN1) 1 4 (4) 48 V (FROM KEY) B+ B+ 0 V = key SW OFF, B+ = key SW ON
2 48 V (FROM KEY) B+ B+ 0 V = key SW OFF, B+ = key SW ON
3 48 VE B1+ B1+
4 48 VE B1+ B1+
5 103 (103) FORWARD LEVER SW High (15 V) Low Activate direction lever from NEU to FWD.
6 104 (104) REVERSE LEVER SW High (15 V) Low Activate direction lever from NEU to REV.
7 107 (107) FOOT BRAKE SW High (15 V) Low Activate foot brake pedal pushed.
8 109 (109) PARKING BRAKE SW Low High (15 V) Activate parking brake lever pulled.
9 111 (111) SEAT SW High (15 V) Low High = seat SW open, Low = seat SW closed
10 EMPTY
11 EMPTY
12 EMPTY
13 EMPTY
14 144 (144) ACCELE SW High (15 V) Low High = accele SW open, Low = accele SW closed
15 (301) FC CONTROL High (15 V) High or Low F/L Truck Type : High = MC, Low = FC
MC MODEL
16 119 LIFT LEVER SW0 High (15 V) Low High = lift lever SW0 open
Low = lift lever SW0 closed
17 120 LIFT LEVER SW1 High (15 V) Low High = lift lever SW1 open
Low = lift lever SW1 closed
18 121 TILT LEVER SW High (15 V) Low High = tilt lever SW open
Low = tilt lever SW closed
19 122 ATTACH 1 LEVER SW High (15 V) Low High = attachment 1 lever SW open,
Low = SW closed
20 123 ATTACH 2 LEVER SW High (15 V) Low Hight = attachment 2 lever SW open,
Low = SW closed
FC MODEL
16 (304) PUMP MOTOR CONTROL 0
4 3 2 1 0 Joystick operation H = High (15 V), L = Low (0 V)

L L L L L → Joystick lever neutral
L L L L H → Joystick lift up (half position)
L L L H L → Joystick lift up (full position)
L L L H H → Joystick tilt forward or backward
L L H L L → Joystick attachment
L L H L H → Joystick lift down
L H H H L → Neutral error (lift and tilt)
Neutral error
H L H H L →
(lift, tilt and attachment)
21 108 (108) GND 0V 0V signal GND
1-30
MAIN CONTROLLER

Logic Wire No. Function Normal Activated Test Procedures
Terminal MC (FC) Voltage Voltage
(CN1) 23 LIFT STOP SW1 High (15 V) Low LIFT Limit Switch 1
24 LIFT STOP SW2 High (15 V) Low LIFT Limit Switch 2
25 LIFT STOP SW3 High (15 V) Low LIFT Limit Switch 3
26 125 (125) RIGHT TRACTION MOTOR Low High (15 V) Activated by over-temp of right traction motor
THERMO.SW
27 128 (128) RIGHT TRACTION MOTOR High (15 V) Low Right traction motor BWI SW
BRUSH SW
28 130 (130) LEFT TRACTION MOTOR Low High (15 V) Activated by over-temp of left traction motor
THERMO SW
29 133 (133) LEFT TRACTION MOTOR High (15 V) Low Left traction motor BWI SW
BRUSH SW
30 135 (135) PUMP MOTOR THERMO. SW Low High (15 V) Activated by over-temp of pump motor
31 138 (136) PUMP MOTOR BRUSH SW High (15 V) Low Pump BWI SW
32 139 (139) BRAKE FLUID SENSOR SW High (15 V) Low Activated by the brake reserver tank empty
33 142 (142) ACCELE ANGLE 0V 0.9 to 4.7 V Activated voltage increases with pushing accele pedal.
34 ANALOG INPUT 0V 0 to 5V SPARE
38 (301) GND 0V 0V signal GND
(CN1) 39 141 (141) 5V 5V 5V 0 V = key SW OFF, 5 V = key SW ON
40 15 V 15 V 15 V 0 V = key SW OFF, 15 V = key SW ON
41 GND 0V 0V signal GND
43 145 (145) R-SPEED SENSOR PHASE A+ 2.3 to 2.5 V Activated voltage increases with vehicle speed increase.
44 EMPTY
45 146 (146) R-SPEED SENSOR PHASE A- Low Low
46 EMPTY
47 147 (147) L-SPEED SENSOR PHASE A+ 2.3 to 2.5 V Activated voltage increases with vehicle speed increase.
48 EMPTY
49 148 (148) L-SPEED SENSOR PHASE A- Low Low
50 EMPTY
51 ALARM OUTPUT1 B1+ Low or B1+ Speed Alarm 1: Low = Alarm
52 EMPTY
53 ALARM OUTPUT2 B1+ Low or B1+ Speed Alarm 2: Low = Alarm
54 EMPTY
55 EMPTY
56 EMPTY
57 EMPTY
58 EMPTY
59 149 (149) DISPLAY TXD High or Low High or Low LCD. Display Tx data : (High = 12 V)
61 150 (150) DISPLAY RXD High or Low High or Low LCD. Display Rx data : (High = 12 V)
62 EMPTY
1-31
MAIN CONTROLLER

Logic Terminal Function Normal Activated Test Procedures
Voltage Voltage
(CN2) 1 GND 0V 0V signal GND
2 48 VE B1+ B1+ 0 V = key SW OFF, B1+ = key SW ON
5 R. FIELD FWD ON/OFF High (5 V) Low R. FIELD FWD: Low = ON, High = OFF
(Activated by traction mode ON)
6 R. FIELD REV ON/OFF High (5 V) Low R. FIELD REV: Low = ON, High = OFF (5 V)
7 R. FIELD FWD PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
8 R. FIELD REV PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
9 L. FIELD FWD ON/OFF High (5 V) Low L. FIELD FWD: Low = ON, High = OFF (5 V)
10 L. FIELD REV ON/OFF High (5 V) Low L. FIELD REV: Low = ON, High = OFF (5 V)
11 L. FIELD FWD PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
12 L. FIELD REV PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
13 R. FIELD ERROR High (15 V) High or Low R. FIELD ERR: Low = error, High = Normal (15 V)
14 L. FIELD ERROR High (15 V) High or Low L. FIELD ERR: Low = error, High = Normal (15 V)
15 R. FIELD CURRENT SIG 0V 0 to 5 V R. FIELD Current: 0 V = OFF, 5 V = MAX
16 R. FIELD CURRENT RTN 0V 0V R. FIELD Current Return
17 L. FIELD CURRENT SIG 0V 0 to 5 V L. FIELD Current: 0 V = OFF, 5 V = MAX
18 L. FIELD CURRENT RTN 0V 0V L. FIELD Current Return
19 EMPTY
20 EMPTY
22 5V 5V 5V 0 V = key SW OFF, 5 V = key SW ON
(CN2) 23 GND 0V 0V signal GND
24 5V 5V 5V 0 V = key SW OFF, 5 V = key SW ON
27 PUMP PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by pump motor ON
28 L. ARMATURE PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
29 R. ARMATURE PWM High (5 V) 0 to 5 V PWM = 0 to 5 V: Activated by traction motor ON
30 R. ARMATURE ERROR High (15 V) High or Low R. Armature error: Low = error
31 L. ARMATURE ERROR High (15 V) High or Low L. Armature error: Low = error
32 PUMP ERROR High (15 V) High or Low Pump error: Low = error
33 48 VPOS B+ B+
34 PUMP MOTOR VOLTAGE Low B+ Low: Line contactor opens
B+: Line contactor closes (no pump motor operation)
35 FRAME VOLTAGE 0V 0V
36 SET SWITCH High (15 V) High or Low SET Switch: Low = SET SW ON
37 DIAG SWITCH High (15 V) High or Low DIAG Switch: Low = DIAG SW ON
1-32
MAIN CONTROLLER

Logic Terminal Function Normal Activated Test Procedures
Voltage Voltage
(CN2) 39 L&R ARMATURE VOLTAGE Low 5 to 20 V Low: Line contactor opens
5 to 20 V: Line contactor closes
(Direction lever in neutral,
accelerator pedal OFF)
40 PUMP Tr. VOLTAGE Low B+ Low: Line contactor opens
B+: Line contactor closes (no pump motor operation)
41 R. Tr. VOLTAGE Low 5 to 20 V Low: Line contactor opens
42 L. Tr. VOLTAGE Low 5 to 20 V Low: Line contactor opens
43 CONT THERMO SENSOR 0 to 5 V 0 to 5 V Controller Temperature
45 R.ARMATURE CURRENT 0 to 0.3 V 0 to 4.2 V R. ARM Current: Activated by traction motor ON
46 R.ARMATURE CURRENT RTN 0V 0V R. Armature Current Return
47 L.ARMATURE CURRENT 0 to 0.3 V 0 to 4.2 V L. ARM Current: Activated by traction motor ON
48 L.ARMATURE CURRENT RTN 0V 0V L. Armature Current Return
49 PUMP CURRENT 0 to 0.3 V 0 to 4.2 V Pump Current: Activated by pump motor ON
50 PUMP CURRENT RTN 0V 0V Pump Current Return
51 15 V 15 V 15 V 15 V = key SW ON, 0 V = key SW OFF
54 EMPTY
55 PUMP CONTACTOR B1+ 0 or 12 V B1+: Contactor opens, 0 or 12 V*: Contactor closes
56 REGEN CONTACTOR B1+ 0 or 12 V B1+: Contactor opens, 0 or 12 V*: Contactor closes
57 LINE CONTACTOR B1+ 0 or 12 V B1+: Contactor opens, 0 or 12 V*: Contactor closes
58 SPARE
59 48 VE B+ B1+ 0 V = key SW OFF, B1+ = key SW ON
*: 36-volt battery : 0 V
48-volt battery : 12 V
1-33
MAIN CONTROLLER
Checking procedure of D9 and Tr1
Checking D9
Check voltages between the anode and cathode terminals
D9
using diode mode of the multimeter. Anode
Multimeter range + lead – lead Measurement Cathode
Diode A C 0.35 to 0.55 V

D9 Cathode
Diode C A OL (∞)
211465
Checking Tr1
Collector
Check voltages between the emitter and base terminals and
between the emitter and collector terminals using diode Tr1
mode of the multimeter.
Multimeter range + lead – lead Measurement
Diode E B OL (∞)
Emitter
Diode B E 0.55 to 0.75 V
Tr1 Base
Collector
Diode C B OL (∞) 211466
Diode B C 0.55 to 0.75 V
Location of D9 and Tr1
D9 LED (green)
CN1
CN2 Tr1 211467
1-34
MAIN CONTROLLER
(2) Head capacitors
. ! WARNING
Disconnect the battery plug before working on the
controller.
! CAUTION
Be careful not to damage the head capacitors.

(c) Remove the positive-side and negative-side busbars
before removing the head capacitors from the
controller.
(d) Visually inspect the head capacitor terminals.
(e) Check to make sure the contents of the head capacitors Positive-side busbar
have not melted or leaked.

(f) Set the multimeter to the 20-kohm range.
Measuring locations
Standard
multimeter Negative-side busbar
(+) terminal (-) terminal indication
206387B
Positive (+) side Negative (-) side
10 kΩ or higher
of head capacitors of head capacitors
NOTE
The above instruction describes the connection of
terminals for a digital multimeter. Reverse the
connections when using an analog multimeter.
(g) If the measured value deviates from the above standard, 2

test individual head capacitors and replace faulty units.
(h) When reinstalling the head capacitors, tighten the
mounting bolts to the specified torque.
Unit: N·m (kgf·m) [lbf·ft] 1
Tightening torque 1
2.94 ± 0.49 (0.3 ± 0.05)
(head capacitor mounting
[2.17 ± 0.36]
bolts)
2
Tightening torque 2 211435
4.41 ± 0.49 (0.45 ± 0.05)
(head capacitor busbar
[3.25 ± 0.36]
and plate mounting bolts)
1-35
MAIN CONTROLLER
(3) Contactor coils

• Resistance test
! WARNING
the controller.
(a) Disconnect the lead wire of coil.

(b) Set the multimeter to 200-ohm range.
(c) Measure coil resistance.
Normal value
Line, pump and

118 to 145 Ω
regeneration contactors
(d) If the measured value deviates from the above range,

replace the contactor assembly.
• Pulse signal test

(a) With the lead wire of contactor coil connected, set the
multimeter to 200-VDC range.
(b) Connect the negative (–) terminal of the multimeter to
the negative-side coil terminal (small fasten terminal)
and the positive (+) terminal of the multimeter to the
positive-side coil terminal (large fasten terminal).
(c) Connect the battery, and operate the control device that
activates the contactor.
(d) The multimeter should indicate approximate battery
voltage after the contactor closes. If the contactor is
found to be normal during the coil resistance test, but
the measured voltage is not within range. Replace the
logic card.
206390A
1-36
MAIN CONTROLLER
(4) Contactor tips

(a) Visually inspect the contactor tips for melting,
adhesion, heat seizure and pitting corrosion.
(b) To check for interference, press the tips and release
them.
(c) Visually inspect the contactor assemblies. Make sure
there are no foreign materials in the assemblies to
interfere with contactor movement.
(d) Measure the gap at each contactor tips using thickness
gauges.
2 N·m
Contactor bridge 205817A
(0.2 kgf·m)
tightening torque
[1.45 lbf·ft]
Contactor tip gap

Unit: mm (in.)
Line contactor 3.15 ± 0.10 (0.12 ± 0.004)
Regeneration contactor 3.15 ± 0.10 (0.12 ± 0.004)
(5) Armature (right) current sensor
! WARNING
controller.

(c) Disconnect connector CN3 from the logic card.
(d) Disconnect current sensor connector CS1.
206391A
1-37
MAIN CONTROLLER
(e) Check continuity at locations indicated below.
Current sensor Pin No. on logic

connector side card harness side
CS1-4GR CN3-51
CS1-3B CN3-63
CS1-2BrY CN3-45
CS1-1LR CN3-46
If there is no continuity, repair or replace wires.

(f) Connect connector CN3 to the logic card.
(g) Set the multimeter to 20-VDC range. (Voltage test)
(h) With connector CS1 disconnected, connect the positive
(+) terminal of the multimeter to CS1-4GR.
Connect the negative (–) terminal of the multimeter to
the NEG terminal.
(i) Connect the battery plug and turn the key switch on.
Standard multimeter indication 14 to 16 V
(j) Then, connect the positive (+) terminal of the

multimeter to CS1-2BrY.

206392A
(k) If both values measured in the above steps (i) and (j) Continuity test
deviate from the specified ranges, replace the logic
card.
! WARNING
are free to turn. CN3-45
(l) Connect connector CS1.

(m) Place wood blocks under the vehicle to lift the front
wheels off the ground. Engage the parking brake.
CS1-4GR
(n) Set the multimeter to 20-VDC range. CS1-2BrY
(o) Connect the positive (+) terminal of the multimeter to
logic card side CN2-45 (harness side CN3-45), and
connect the negative (–) terminal to the NEG terminal. 211436
Voltage test
1-38
MAIN CONTROLLER
Standard multimeter indication 0 to 0.3 V
If the measured value deviates from the above standard,

repair or replace wires.
(p) Shift the direction lever to Forward. Gradually depress
the accelerator pedal (with front wheels raised) and
read the voltage change.
Voltage increase Normal
Voltage at 0 or no change Replace current sensor.
(6) Armature (left) current sensor
. ! WARNING
the controller.

206391A
1-39
MAIN CONTROLLER MAIN CONTROLLER

CS2-4GR CN3-52
CS2-3B CN3-63
CS2-2LO CN3-47
CS2-1BrW CN3-48

(g) Set the multimeter to the 20-VDC range. (Voltage test)
the NEG terminal.

multimeter to CS2-2LO.

206392A
card.
1-40
MAIN CONTROLLER
! WARNING
The lift truck can move suddenly. Injury to CN3-47
are free to turn.
(l) Connect connector CS2. CS2-4GR

(m) Place wood blocks under the vehicle to lift the front CS2-2LO

(n) Set the multimeter to 20-VDC range.
211437
Voltage test
connect the negative (–) terminal to the NEG terminal.

repair or replace the wires.
(p) Shift the direction lever to Forward. Gradually depress
the accelerator pedal (with front wheels raised) and
read voltage change.
(7) Pump current sensor
! WARNING
the controller.

206391A
1-41
MAIN CONTROLLER

CS3-4GR CN3-53
CS3-3B CN3-63
CS3-2Br CN3-49
CS3-1YG CN3-50

(g) Set the multimeter to the 20-VDC range. (Voltage test)
the NEG terminal.

multimeter to CS3-2Br.

206392A
card.
! WARNING
are free to turn. CN3-49
(l) Connect connector CS3.

(m) Place wood blocks under the vehicle to lift the front
CS3-4GR
(n) Set the multimeter to the 20-VDC range. CS3-2Br
211438
connect the negative (–) terminal to the NEG terminal.
Voltage test
1-42
MAIN CONTROLLER

repair wires.
(p) Gradually pull the lift lever (lifting operation) and read
voltage change.
(8) Diodes
! WARNING
the controller.
The following describes the inspection procedure for diode

D1R.
Follow the same procedure for all other diodes.
206394A
(c) Remove the busbar and other parts from diode D1R.
(d) Set the multimeter to diode range, and measure voltage
between the following terminals.
Measuring locations Standard multimeter

Test rod (+) terminal (–) terminal indication
Forward
direction Anode side of D1R Cathode side of D1R 0.1 to 0.3 V
Reverse
direction Cathode side of D1R Anode side of D1R Infinite (∞)
NOTE
If the resistance range is used to measure voltage of the
reverse direction, the multimeter indicates infinite ohm
(∞ Ω).
(e) If the measured values deviate from the standard,

replace the diode.
1-43
MAIN CONTROLLER
• Replacement procedure
! WARNING
the controller.

(c) Remove the logic card.
(d) Remove the busbar and other parts, then remove the
diode. 206395
(e) Clean contact surfaces ➀ , and place a silicone sheet

under the diode.
(f) Install the diode, and tighten mounting bolts to the
following torque.
(g) Connect the busbar and other parts.
Diode Tightening torque
4.41 ± 0.49 N·m

D1R, D1L, D1P, D2 (0.45 ± 0.05 kgf·m)
[3.25 ± 0.36 lbf·ft]
(9) Drive board

• On-vehicle test
! WARNING
the controller.
Inspection before test

(a) Inspect head capacitors.
(b) Inspect diodes D1R, D1L, D1P and D2.
(c) Inspect IGBTs T1D and T2D. 207468
(d) Inspect current sensors.
(e) Check continuity between drive board CN1 and logic
card.
1-44
MAIN CONTROLLER
Drive board CN1 continuity test
Drive board CN1 Pin No. on logic card side

connector side
CN1-1 B CN2-25
CN1-2 R CN2-26
CN1-3 BrR CN2-24
CN1-4 Br CN2-27
CN1-5 BrW CN2-28
CN1-6 LR CN2-29
CN1-9 B CN2-23
CN1-10 G CN2-32
CN1-11 YL CN2-31
CN1-12 YG CN2-30
(f) Remove the head capacitors.

(g) Check continuity between drive board CN2 and logic
card.
Drive board CN2 continuity test

Drive board CN2 Terminal on
connector side IGBT side
CN2-7 R IGBT T1R - Gate terminal
CN2-8 WR IGBT T1R - Emitter terminal
CN2-1 GR IGBT T1R - Collector terminal
CN2-3 L IGBT T1L - Gate terminal
CN2-2 WL IGBT T1L - Emitter terminal
CN2-4 GL IGBT T1L - Collector terminal
CN2-6 Y IGBT T1P - Gate terminal
CN2-5 WY IGBT T1P - Emitter terminal
207469
CN2-12 GY IGBT T1P - Collector terminal
Conduct the following tests. If abnormalities are

found, replace the drive board.
NOTE
Handle the G (gate) and E (emitter) terminals with
extreme care since they can be easily damaged by
static electricity.
(Do not touch the G and E terminals.)
1-45
MAIN CONTROLLER
IGBT OFF test

(a) Disconnect the battery plug.
(b) Remove the line fuse.
(c) Disconnect the gate and emitter wires of IGBTs T1R,
T1L and T1P.
(d) Connect the battery plug, and turn the key switch on.
(e) Set the multimeter to 200-VDC range.
(f) Measure voltages between disconnected gate and
emitter wires.
Measuring locations
Standard 206397A
multimeter
T1R gate T1R emitter

–9 to +16 V
terminal R terminal WR
T1L gate T1L emitter

–9 to +16 V
terminal L terminal WL
T1P gate T1P emitter

–9 to +16 V
terminal Y terminal WY
Drive IGBT ON test

(a) Turn the key switch off, and disconnect the battery
plug.
(b) Connect the gate and emitter wires to original
positions.
(c) Connect the battery plug, and turn the key switch on.
(d) Shift the direction lever to either Forward or Reverse.
(e) Depress the accelerator pedal, and measure voltages
between connected gate and emitter wires.
Measuring locations 207469

Standard
multimeter
T1R gate T1R emitter

–9 to +16 V
terminal R terminal WR
T1L gate T1L emitter

–9 to +16 V
terminal L terminal WL
If no abnormality is found in the IGBT OFF and ON

tests, replace the drive board and T1R or T1L.
1-46
MAIN CONTROLLER
Pump motor IGBT ON test

(a) Turn the key switch off, and disconnect the battery
plug.
(b) Connect the gate and emitter wires to original
positions.
(c) Connect the battery plug, and turn the key switch on.
(d) Set the lift speed to maximum setting using the
program option.
(e) Pull the lift lever, and measure voltages between
connected gate and emitter wires.
Measuring locations 207470

Standard
multimeter
T1P gate T1P emitter

–9 to +16 V
terminal Y terminal WY
If no abnormality is found in the IGBT OFF and ON

tests, replace the drive board and T1P.
• Unit test
Disconnect the terminals, and inspect the test circuits indicated below. If abnormalities are found, replace the
drive board.
CN2
CN1
206400A
Diagram of drive motor drive board terminal connections
1-47
MAIN CONTROLLER
Drive Board CN1 Test (Off Vehicle)

Terminal Function Multimeter + – Results
(CN1) Range Lead Lead
CN1- 1 Power supply input circuit 20 kΩ CN1-2 CN1-1 10 kΩ or higher
2
3 T1P pulse input circuit Diode CN1-3 CN1-4 1.2 to 1.8 V
4 CN1-4 CN1-3 OL (∞)
5 T1L pulse input circuit Diode CN1-3 CN1-5 1.2 to 1.8 V
CN1-5 CN1-3 OL (∞)
6 T1R pulse input circuit Diode CN1-3 CN1-6 1.2 to 1.8 V
CN1-6 CN1-3 OL (∞)
9 T1P error signal output circuit 20 kΩ CN1-10 CN1-9 OL (∞)
10 CN1-9 CN1-10 OL (∞)
11 T1L error signal output circuit 20 kΩ CN1-11 CN1-9 OL (∞)
CN1-9 CN1-11 OL (∞)
12 T1R error signal output circuit 20 kΩ CN1-12 CN1-9 OL (∞)
CN1-9 CN1-12 OL (∞)
Drive Board CN2 Test (Off Vehicle)

(CN2) Range Lead Lead
CN2- 1 T1R output circuit (between E and G) 20 kΩ CN2-1 CN2-8 OL (∞)
8 CN2-8 CN2-1 OL (∞)
7 T1R output circuit (between E and C) 20 kΩ CN2-7 CN2-8 10 kΩ or higher
8 CN2-8 CN2-7 10 kΩ or higher
4 T1L output circuit (between E and C) 20 kΩ CN2-4 CN2-9 OL (∞)
9 CN2-9 CN2-4 OL (∞)
9 T1L output circuit (between E and G) 20 kΩ CN2-10 CN2-9 10 kΩ or higher
5 T1P output circuit (between E and C) 20 kΩ CN2-12 CN2-5 OL (∞)
12 CN2-5 CN2-12 OL (∞)
5 T1P output circuit (between E and G) 20 kΩ CN2-6 CN2-5 10 kΩ or higher
NOTE
With multimeter set up in the resistance measurement range, the positive meter lead is applied to the positive
terminal of the power supply and negative meter lead is applied to the negative terminal of the power supply.
E: EMITTER
C: COLLECTOR
G: GATE
(10) H bridge board
! WARNING
the controller.

(c) Remove the logic card and drive board.
Inspection of H bridge board installation condition

(a) Set the multimeter to 20-kohm range, and measure
207471
resistance between NEG and heat sink blocks.
1-48
MAIN CONTROLLER
Measuring locations
Standard
multimeter
Heat sink A NEG 10 kΩ or higher
Heat sink B NEG 10 kΩ or higher
Heat sink C NEG 10 kΩ or higher
Heat sink D NEG 10 kΩ or higher
NOTE
On heat sink, measurement should be taken on 5.5 mm2
(0.0085 in.2) area at harness terminal mounting location.
(b) Set the multimeter to 20-kohm range, and measure

resistance between the POS plate and heat sink blocks.
Measuring locations
Standard
multimeter
POS plate Heat sink A 10 kΩ or higher
POS plate Heat sink B 10 kΩ or higher
POS plate Heat sink C 10 kΩ or higher
POS plate Heat sink D 10 kΩ or higher
NOTE
On heat sink, measurement should be taken on 5.5 mm2
(0.0085 in.2) area at harness terminal mounting location.
If the results of the above tests (a) and (b) deviate from
the standards, conduct the following tests.
(c) Conduct a unit test with the H bridge board.
(d) Set the multimeter to 200-ohm range, and measure
resistance between heat sinks A and B and between
heat sinks C and D.
Measuring locations
Standard
multimeter
Heat sink A Heat sink B 0.5 to 1.5 Ω
Heat sink C Heat sink D 0.5 to 1.5 Ω
(e) If the results of the above test (d) deviate from the
standards, inspect the drive motor field circuits and
wiring, and insulation between heat sink blocks A, B
and base plates.
1-49
MAIN CONTROLLER
(f) Check continuity between H bridge board connector

CN2 and the logic card.
H bridge connector continuity test
CN2 connector side Pin No. on logic

card side
CN2-1 BrR CN2-22
CN2-2 B CN2-21
CN2-3 GB CN2-15
CN2-4 GW CN2-16
CN2-5 G CN2-17
CN2-6 GL CN2-18
CN2-7 LB CN2-9
CN2-8 LY CN2-10
CN2-9 BrR CN2-5
CN2-10 BrY CN2-6
CN2-11 LR CN2-11
CN2-12 LO CN2-12
CN2-13 BrW CN2-7
CN2-14 Br CN2-8
CN2-15 YG CN2-14
CN2-16 YL CN2-13
CN2-17 R CN2-2
CN2-18 R CN2-4
CN2-19 B CN2-1
CN2-20 B CN2-3
• Unit test
Disconnect the terminals, and inspect the test circuits indicated below. If abnormalities are found, replace the H
bridge board.
CN2 connector pin Nos.
CN2
211439
Diagram of H bridge board terminal connections

1-50
MAIN CONTROLLER
H Bridge Board Test (Off Vehicle)

Range Lead Lead
CN2 1 Power supply input circuit 20 kΩ CN2-1 CN2-2 10 kΩ or higher
2 (5 V GND)
3 Current output 20 kΩ CN2-3 CN2-4 5 to 6 kΩ
4 (R. FIELD CURRENT, RETURN) CN2-4 CN2-3 5 to 6 kΩ
5 Current output 20 kΩ CN2-5 CN2-6 5 to 6 kΩ
6 (L/ FIELD CURRENT, RETURN) CN2-6 CN2-5 5 to 6 kΩ
7 Pulse input circuit Diode CN2-7 CN2-1 OL (∞)
(L. FIELD FWD ON/OFF) CN2-1 CN2-7 1.2 to 1.8 V
(L. FIELD REV ON/OFF) CN2-1 CN2-8 1.2 to 1.8 V
(R. FIELD FWD ON/OFF) CN2-1 CN2-9 1.2 to 1.8 V
(R. FIELD REV ON/OFF) CN2-1 CN2-10 1.2 to 1.8 V
(L. FIELD FWD PWM) CN2-1 CN2-11 1.2 to 1.8 V
(L. FIELD REV PWM) CN2-1 CN2-12 1.2 to 1.8 V
(R. FIELD FWD PWM) CN2-1 CN2-13 1.2 to 1.8 V
(R. FIELD REV PWM) CN2-1 CN2-14 1.2 to 1.8 V
15 Error signal output circuit 20 kΩ CN2-15 CN2-2 OL (∞)
(L. FIELD ERROR) CN2-2 CN2-15 OL (∞)
16 Error signal output circuit 20 kΩ CN2-16 CN2-2 OL (∞)
(R. FIELD ERROR) CN2-2 CN2-16 OL (∞)
17 Power supply input circuit 20 kΩ CN2-17 CN2-19 10 kΩ or higher
18 (48 VE, GND) CN2-18 CN2-20 10 kΩ or higher
19
20
FET, L Output circuit 20 kΩ FET5 (fin) NEG (busbar) OL (∞)
(L.R. ON/OFF (FET5)) NEG (busbar) FET5 (fin) OL (∞)
Output circuit 20 kΩ FET3 (fin) FET6 (busbar) OL (∞)
(L.R. PWM (FET3)) FET6 (busbar) FET3 (fin) OL (∞)
Output circuit 20 kΩ FET6 (fin) NEG (busbar) OL (∞)
(L.F. ON/OFF (FET6)) NEG (busbar) FET6 (fin) OL (∞)
(L.F. PWM (FET4)) FET5 (busbar) FET4 (fin) OL (∞)
FET, R Output circuit 20 kΩ FET7 (fin) NEG (busbar) OL (∞)
(R.R. ON/OFF (FET7)) NEG (busbar) FET7 (fin) OL (∞)
(R.R. PWM (FET1)) FET8 (busbar) FET1 (fin) OL (∞)
Output circuit 20 kΩ FET8 (fin) NEG (busbar) OL (∞)
(R.F. ON/OFF (FET8)) NEG (busbar) FET8 (fin) OL (∞)
(R.F. PWM (FET2)) FET7 (busbar) FET2 (fin) OL (∞)
NOTE
With multimeter set up in the resistance measurement range, the positive meter lead is applied to the positive
terminal of the power supply and negative meter lead is applied to the negative terminal of the power supply.
1-51
MAIN CONTROLLER
Procedure for replacing H bridge board

(1) Disconnect the battery plug (for safety).
206994
(2) Loosen four screws (M4×8) with washers from bracket

D located on the logic card.
➀
➁
➂
➃
207474B
(3) Remove bracket D.

Bracket D
207475B
1-52
MAIN CONTROLLER
(4) Disconnect the cable from the yellow connector of the

logic board.
Cable
207473A
(5) Loosen five screws (M4×8) with washers from bracket

E located under the logic board. ➀➁
➂
➃
➄
207474A
(6) Remove bracket E together with the logic board.

Bracket E with
logic board
207475A
1-53
MAIN CONTROLLER
(7) Disconnect the harness from the black connector of the

drive board assembly. Loosen four screws (M3×6) ➀
with washers from the drive board assembly. ➁
➃ ➂
Harness
207476A
(8) Loosen three screws (M6×14) with washers from

bracket C, then remove bracket C.
Bracket C ➀
➂ ➁
207477A
(9) Loosen the screw (M6×14) that connects cable B

(16A50-03602) to bus plate A.
Bus plate A ➀ Cable B

207478A
1-54
MAIN CONTROLLER
(10) Loosen the four screws (M3×6) with washer that

connects bracket A to the H bridge board assembly. Bracket A
3
2
1
211440
(11) Loosen eight screws (M3×8) with washers from the MOS-FET ➀➁➂➃
MOS-FETs on the H bridge board assembly.
➇ ➆ ➅ ➄
207478C
(12) Remove the H bridge board assembly from the

controller.
Loosen the screw (M5×10) with washer that connects
the cable, then disconnect harness A.
Cable B
NOTE
After dismounting the H bridge board assembly from
1
the controller, harness A can be disconnected easily
from the connector. 2
Harness A
Gently jiggle harness A to disconnect.
211441
1-55
MAIN CONTROLLER
(13) Wipe thermal paste from the surface of aluminum heat Heat sink A
sink A. Clean heat sink B with a clean cloth.
NOTE
If old thermal paste or dust remains on the surface of
the heat sink, damage can occur to the H bridge board
circuits due to reduced heat dissipation.
Heat sink B
207480A
(14) Connect cable B using the screw (M5×10) with

washer, and connect harness A to the H bridge board
assembly.
Cable B
1
2
Harness A
211441
1-56
MAIN CONTROLLER
(15) Apply a thin and uniform thermal paste to the back

side of each MOS-FET. ➀ ➁ ➂ ➃
When reusing the H bridge board assembly, wipe old
thermal paste completely and apply new thermal
paste.
NOTE
1) Apply thermal paste in a thickness of 100 to 200
µm.
The thermal paste coat should feel extremely thin
to the touch. ➇ ➆ ➅ ➄ 207481
(Make sure the thermal paste coat is not too thick
or too thin.)
2) Do not apply thermal paste to the surfaces or
metallic-parts of the MOS-FETs.
(If metallic-parts are coated with thermal paste,
field current cannot flow and a malfunction can
result.)
3) Be careful not to bend or break the legs of the
MOS-FETs.
(16) Mount the H bridge board assembly in the controller. MOS-FET ➀➁➂➃
Install the eight screws (M3×8) with washers (05847-
00308) to mount the MOS-FETs.
➇ ➆ ➅ ➄
207478C
(17) Install the four screws (M3×6) with washer to mount

bracket A on the H bridge board assembly. Bracket A
3
2
1
211440
1-57
MAIN CONTROLLER
(18) Fasten the eight screws (M3×8) with washers tightly MOS-FET ➀➁➂➃
to secure the MOS-FETs in place.
Unit: N·m (kgf·m) [lbf·ft]
M3 screw 0.98 ± 0.20 (0.10 ± 0.02)
tightening torque [0.72 ± 0.15]
NOTE
Be careful not to tighten the M3 x 8 screws with
excessive force in order to prevent damage to
aluminum heat sink A and B. ➇ ➆ ➅ ➄
207478C
(19) Check continuity (0 Ω) between the metallic part

(excluding M3×8 screw) of each MOS-FET and heat
sink A (and B) using a multimeter.
207482
(20) Install the screw (M6×14) with washer to connect

cable B to bus plate A.
Bus plate A ➀ Cable B

207478A
1-58
MAIN CONTROLLER
(21) Install the three screws (M6×14) with washers to

install bracket C.
Bracket C ➀
➂ ➁
207477A
(22) Install the four screws (M3×6) with washers to mount

the drive board assembly. ➀
Connect the harness to the black connector of the ➁
drive board assembly.
➃ ➂
Harness
207476A
(23) Install bracket E mounted with the logic board to the

controller.
Bracket E with
logic board
207475A
1-59
MAIN CONTROLLER
(24) Install the five screws (M4×8) with washers to bracket

E (underplate of the logic board), and tighten to 1.5 ➀➁
N·m (15 kgf·cm) [1.08 lbf·ft].
➂
➃
➄
207474A
(25) Connect the cable to the yellow connector of the logic

board.
Cable
207473A
(26) Mount bracket D, then install the four screws (M4×8)

with washers and tighten to 1.5 N·m (15 kgf·cm) [1.08
Bracket D
lbf·ft].
207475B
(27) H bridge board replacement is completed. ➀

➁
➂
➃
207474B
1-60
MAIN CONTROLLER
(11) IGBTs
! WARNING
controller.
The following describes the inspection procedure for IGBT

T1R.
Follow the same procedure for all other IGBTs.
Preparation
(c) Remove the busbar and harness from T1R.
G-E short-circuit test

(a) Short terminals G and E with a wire.
(b) Set the multimeter to 200-ohm range, and measure
resistance between the following terminals.
Harness
Measuring locations
Multimeter Busbar
Test rod (+) terminal (-) terminal indication
➀ Terminal C Terminal E ∞ 206408A
➁ Terminal E Terminal C Several MΩ
Resistance values should have the following

relationship.
Resistance ➀ > Resistance ➁
NOTE C
Handle the G and E terminals with extreme care since E

they can be easily damaged by static electricity.
(Do not touch the G and E terminals.)
E G
206409
1-61
MAIN CONTROLLER
• G-E resistance test

(a) Set the multimeter to 200-ohm range, and measure
resistance between terminals G and E.
Measuring locations Multimeter indication
Terminals G and E ∞
NOTE
It takes some time for the multimeter to indicate
infinity (∞) in normal condition.
206410
(b) If the results of the G-E short-circuit and resistance
tests deviate from the standards, replace the IGBT.
• Replacement procedure
! WARNING
the controller.

(c) Remove the logic card.
(d) Remove the busbar and other parts, then remove the
IGBT.
(e) Clean contact surfaces ➀.
(f) Place a silicone sheet under the IGBT.
(g) Install the IGBT, and tighten to the specified torque.
IGBT Tightening torque

206395
4.41 ± 0.49 N·m (0.45 ± 0.05 kgf·m)
T1R, T1L, T1P
[3.25 ± 0.36 lbf·ft]
NOTE
New IGBTs are provided with black sponges to protect
the G and E terminals from damage caused by static
electricity. Do not remove the sponges until the G and
E terminals are connected.
(h) Install the busbar and other parts.
1-62
MAIN CONTROLLER
(12) Controller thermister
! WARNING
controller.
(a) Disconnect the thermister connector.

(b) Set the multimeter to 200-kohm or 20-kohm range.
(c) Measure temperature at the test site, and allow the
thermister temperature to cool, before measuring
resistance at the connector. 206413A
(d) Compare the measured value with the values in the
table on the following page. If the measured value
deviates from the specified range, replace the
thermister.
1-63
MAIN CONTROLLER
Standard resistance-temperature relationships
Temperature Lower limit Standard value Upper limit

°C kΩ kΩ kΩ
–20.0 427.4 487.4 555.3
–19.0 403.6 459.6 523.0
–18.0 381.2 433.6 492.8
–17.0 360.2 409.3 464.6
–16.0 340.6 386.5 438.1
–15.0 322.1 365.0 413.4
–14.0 304.7 344.9 390.1
–13.0 288.4 326.1 368.4
Voltage
–12.0 273.0 308.4 348.0

–11.0 258.6 291.7 328.8
–10.0 245.0 276.1 310.8
–9.0 232.2 261.4 293.9
–8.0 220.2 247.5 278.0
–7.0 208.8 234.5 263.1
–6.0 198.1 222.2 249.1
–5.0 188.0 210.7 235.9
–4.0 178.5 199.8 233.5
–3.0 169.6 189.6 211.8
–2.0 161.1 179.9 200.8
–1.0 153.1 170.8 190.4
4.8 V 0.0 145.6 162.2 180.6
1.0 138.4 154.1 171.4
2.0 131.6 146.4 162.6
3.0 125.2 139.1 154.4
4.0 119.2 132.3 146.6
4.74 V 5.0 113.5 125.8 139.3
6.0 108.0 119.7 132.4
7.0 102.9 113.9 125.9
8.0 98.07 108.4 119.7
9.0 93.48 103.2 113.9
4.68 V 10.0 89.14 98.32 108.4
11.0 85.02 93.68 103.1
12.0 81.11 89.29 98.21
13.0 77.41 85.13 93.55
14.0 73.89 81.19 89.13
4.60 V 15.0 70.56 77.45 84.95
16.0 67.40 73.91 80.98
17.0 64.39 70.55 77.23
18.0 61.54 67.36 73.67
19.0 58.83 64.34 70.29
4.50 V 20.0 56.26 61.47 67.09
R (100°C) = 3.3 kΩ ± 3%
B (0/100) = 3970 K ± 2%
1-64
MAIN CONTROLLER

°C kΩ kΩ kΩ
20.0 56.26 61.47 67.09
Voltage
21.0 53.81 58.74 64.06

22.0 51.48 56.15 61.18
23.0 49.27 53.68 58.44
24.0 47.17 51.34 55.84
4.39 V 25.0 45.16 49.12 53.38
26.0 43.26 47.00 51.03
27.0 41.44 44.99 48.80
28.0 39.71 43.08 46.68
29.0 38.06 41.25 44.67
4.27 V 30.0 36.49 39.52 42.75
31.0 35.00 37.86 40.93
32.0 33.57 36.29 39.19
33.0 32.21 34.79 37.54
34.0 30.91 33.36 35.97
4.12 V 35.0 29.67 32.00 34.47
36.0 28.49 30.70 33.04
37.0 27.36 29.46 31.68
38.0 26.29 28.27 30.38
39.0 25.26 27.14 29.14
3.97 V 40.0 24.27 26.06 27.96
41.0 23.33 25.04 26.84
42.0 22.43 24.05 25.76
43.0 21.58 23.11 24.74
44.0 20.75 22.22 23.76
3.79 V 45.0 19.97 21.36 22.82
46.0 19.22 20.54 21.93
47.0 18.50 19.75 21.08
48.0 17.81 19.00 20.26
49.0 17.15 18.29 19.48
3.61 V 50.0 16.52 17.60 18.73
51.0 15.91 16.94 18.02
52.0 15.33 16.31 17.34
53.0 14.78 15.71 16.68
54.0 14.25 15.13 16.06
3.41 V 55.0 13.74 14.58 15.46
56.0 13.25 14.05 14.89
57.0 12.78 13.54 14.34
58.0 12.33 13.05 13.81
59.0 11.89 12.59 13.31
3.20 V 60.0 11.48 12.14 12.83
R (100°C) = 3.3 kΩ ± 3%
B (0/100) = 3970 K ± 2%
1-65
MAIN CONTROLLER

°C kΩ kΩ kΩ
60.0 11.48 12.14 12.83
Voltage
61.0 11.08 11.71 12.37

62.0 10.70 11.30 11.92
63.0 10.33 10.90 11.50
64.0 9.978 10.52 11.09
3.0 V 65.0 9.640 10.16 10.70
66.0 9.314 9.809 10.32
67.0 9.001 9.473 9.961
68.0 8.700 9.150 9.614
69.0 8.411 8.840 9.282
2.78 V 70.0 8.133 8.541 8.963
71.0 7.865 8.255 8.656
72.0 7.607 7.979 8.362
73.0 7.360 7.714 8.079
74.0 7.121 7.459 7.807
2.57 V 75.0 6.892 7.214 7.545
76.0 6.671 6.978 7.294
77.0 6.458 6.751 7.052
78.0 6.253 6.533 6.819
79.0 6.055 6.322 6.595
2.36 V 80.0 5.865 6.120 6.380
81.0 5.682 5.925 6.173
82.0 5.505 5.737 5.973
83.0 5.335 5.556 5.781
84.0 5.170 5.381 5.596
2.17 V 85.0 5.012 5.213 5.418
86.0 4.859 5.051 5.246
87.0 4.712 4.895 5.081
88.0 4.570 4.744 4.921
89.0 4.433 4.599 4.768
1.98 V 90.0 4.300 4.459 4.620
91.0 4.172 4.324 4.477
92.0 4.049 4.193 4.339
93.0 3.930 4.068 4.207
94.0 3.814 3.946 4.079
1.80 V 95.0 3.703 3.829 3.955
96.0 3.596 3.716 3.836
97.0 3.492 3.606 3.721
98.0 3.392 3.501 3.610
99.0 3.295 3.399 3.503
1.63 V 100.0 3.201 3.300 3.399
R (100°C) = 3.3 kΩ ± 3%
B (0/100) = 3970 K ± 2%
1-66
MAIN CONTROLLER
(13) Right pulse sensor (Speed sensor 1)

(a) Turn the key switch off. Right pulse sensor
(c) Remove the logic card cover, and disconnect connector
CN3.
(d) Disconnect the right pulse sensor connector.
Also check CN11.
Right pulse sensor Logic card

connector side harness side 211442
CN16-145Y CN3-43
CN16-146B CN3-45

(g) Measure resistance between CN16-145Y and CN16-
146B on the sensor side of the right pulse sensor
connector.
Standard multimeter indication 2.1 to 2.5 kΩ
If the measured value deviates from the standard,

replace the right pulse sensor.
206417
(14) Left pulse sensor (Speed sensor 2)

(c) Remove the logic card cover, and disconnect connector
CN3.
(d) Disconnect the left pulse sensor connector.
Also check CN11.
Left pulse sensor Logic card

211443
connector side harness side
CN15-147L CN3-47
CN15-148G CN3-49

1-67
MAIN CONTROLLER

(g) Measure resistance between CN15-147L and CN15-
148G on the sensor side of the left pulse sensor
connector.
Standard multimeter indication 2.1 to 2.5 kΩ
If the measured value deviates from the standard,

replace the left pulse sensor.
206415
1-68
MAIN CONTROLLER
Service Data
Multimeter
Parts to be tested Standard value
(+) terminal (–) terminal
Logic card volume POS NEG Battery voltage
Logic card — — Refer to logic card
voltage measurement table
Contactor coils (line, pump and (+) coil terminal (–) coil terminal 118 to 145 Ω
regeneration coils)
Contactor coils (line, pump and (+) coil terminal (–) coil terminal 23.4 to 52 V
regeneration coils)
(pulse signal) (small fasten terminal) (large fasten terminal) (after coil activation)
Current sensors (continuity on CS1-1 LR CN3-46
current sensor connector side CS1-2 BrY CN3-45
and logic card harness side) CS1-3 B CN3-63
CS1-4 GR CN3-51
CS2-1 BrW CN3-48
CS2-2 LO CN3-47 Confirmation
CS2-3 B CN3-63 of continuity
CS2-4 GR CN3-52
CS3-1 YG CN3-50
CS3-2 Br CN3-49
CS3-3 B CN3-63
CS3-4 GR CN3-53
CS1-4 GR
CS2-4 GR NEG 14 to 16 V
CS3-4 GR
CS1-2 BrY
CS2-2 LO NEG 4 to 6 V
CS3-2 Br
P3-45
P3-49 NEG 0 to 0.3 V
Diodes (diode range) Anode side Cathode side 0.1 to 0.3 V

Cathode side Anode side ∞
1-69
MAIN CONTROLLER
Multimeter
Drive board Drive board connector Pin No. on logic card
CN1 side harness side
CN1-1 B CN2-25
CN1-2 R CN2-26
CN1-3 BrR CN2-24
CN1-4 Br CN2-27 Confirmation
CN1-5 BrW CN2-28 of continuity
CN1-6 LR CN2-29
CN1-9 B CN2-23
CN1-10 G CN2-32
CN1-11 YL CN2-31
CN1-12 YG CN2-30
Drive board connector Terminals
CN2 side on IGBT side
CN2-7 R IGBT T1R-Gate terminal
CN2-8 WR IGBT T1R-Emitter terminal
CN2-1 GR IGBT T1R-Collector terminal Confirmation
CN2-3 L IGBT T1L-Gate terminal of continuity
CN2-2 WL IGBT T1L-Emitter terminal
CN2-4 GL IGBT T1L-Collector terminal
CN2-6 Y IGBT T1P-Gate terminal
CN2-5 WY IGBT T1P-Emitter terminal
CN2-12 GY IGBT T1P-Collector terminal
(IGBT OFF test) T1R gate terminal R T1R emitter terminal WR –9 to + 16 V
T1L gate terminal L T1L emitter terminal WL –9 to + 16 V
T1P gate terminal Y T1P emitter terminal WY –9 to + 16 V
1-70
MAIN CONTROLLER
Multimeter
Drive board
(IGBT ON test) T1R gate terminal R T1R emitter terminal WR –9 to +16 V
T1L gate terminal L T1L emitter terminal WL –9 to +16 V
T1P gate terminal Y T1P emitter terminal WY –9 to +16 V
(Unit test) — — Refer to section on
unit test of drive board
H bridge board Heat sink A NEG
Heat sink B NEG 10 kΩ or higher
Heat sink C NEG (Range: 20 kΩ)
Heat sink D NEG
POS plate Heat sink A
POS plate Heat sink B 10 kΩ or higher
POS plate Heat sink C (Range: 20 kΩ)
POS plate Heat sink D
Heat sink A Heat sink B 0.5 to 1.5 Ω
Heat sink C Heat sink D (Range: 200 Ω)
H bridge board Pin No. on logic
connector CN2 side card harness side
CN2-1 BrR CN1-22
CN2-2 B CN1-21
CN2-3 GB CN1-15
CN2-4 GW CN1-16
CN2-5 G CN1-17
CN2-6 GL CN1-18
CN2-7 LB CN1-9
CN2-8 LY CN1-10
CN2-9 BrR CN1-5
CN2-10 BrY CN1-6 Confirmation
CN2-11 LR CN1-11 of continuity
CN2-12 LO CN1-12
CN2-13 BrW CN1-7
CN2-14 Br CN1-8
CN2-15 YG CN1-14
CN2-16YL CN1-13
CN2-17 R CN1-2
CN2-18 R CN1-4
CN2-19 B CN1-1
CN2-20 B CN1-3
(Unit test) — — Refer to section on
unit test of drive board
1-71
MAIN CONTROLLER
Multimeter
IGBT
(G-E short-circuit test) Terminal C Terminal E ∞
Terminal E Terminal C Several M Ω
(G-E resistance test) Terminal G Terminal E ∞
Thermistor Refer to thermistor
Thermistor connector (no polarity)
characteristic table
Right pulse sensor CN16-145 Y CN3-43 Confirmation of continuity
(Continuity) CN16-146 B CN3-45 Confirmation of continuity
(Resistance) CN16-145 Y CN16-146 B 2.1 to 2.5 kΩ
Left pulse sensor CN15-147 L CN3-47 Confirmation of continuity
(Continuity) CN15-148 G CN3-49 Confirmation of continuity
(Resistance) CN15-147 L CN15-148 G 2.1 to 2.5 kΩ
1-72
MAIN CONTROLLER
Tightening Torque
5, 6
2 9
7
4
8
1
207486A
Unit: N·m (kgf·m) [lbf·ft]
Tightened parts Quantity Tightening torque

1 Stud terminals 7 11.77 ± 1.96 (1.2 ± 0.2) [8.68 ± 1.45]
2 Head capacitor bus plates 6 4.41 ± 0.49 (0.45 ± 0.05) [3.25 ± 0.36]
3 Head capacitors 12 2.94 ± 0.49 (0.3 ± 0.05) [2.17 ± 0.36]
4 Contactor bridges 2 2.0 ± 0.5 (0.2 ± 0.05) [1.45 ± 0.36]
5 Diodes D1D through D2P 6 4.41 ± 0.49 (0.45 ± 0.05) [3.25 ± 0.36]
6 Diodes D5D 4 4.41 ± 0.49 (0.45 ± 0.05) [3.25 ± 0.36]
7 IGBTs 8 4.41 ± 0.49 (0.45 ± 0.05) [3.25 ± 0.36]
8 Contactor terminals 4 11.77 ± 1.96 (1.2 ± 0.2) [8.68 ± 1.45]
9 Logic card cover 9 1.47 ± 0.20 (0.15 ± 0.02) [1.08 ± 0.14]
1-73
TROUBLESHOOTING FOR CONTROL CIRCUITS
General Information ............................................................................... 2– 1

Electrical System Diagram .................................................................. 2– 3
Alarm List ................................................................................................. 2– 5
E0 Right Motor, Overheating .............................................................. 2– 7
E1 Left Motor, Overheating ................................................................ 2– 9
E2 Pump Motor, Overheating ............................................................. 2 – 11
E3 Controller, Overheating ................................................................. 2 – 13
E4 Right Motor, Worn Brushes .......................................................... 2 – 15
E5 Left Motor, Worn Brushes ............................................................. 2 – 17 2
E6 Pump Motor, Worn Brushes ......................................................... 2 – 19
Brake Oil, Low Level ....................................................................... 2 – 21
10 Right Motor, Faulty Armature Circuit ......................................... 2 – 23
11 Right Motor, Transistor Wire Breakage ..................................... 2 – 26
12 Right Motor, Shorted Transistor .................................................. 2 – 28
13 Right Motor, Faulty Transistor Drive .......................................... 2 – 30
14 Right Motor, Faulty Current Sensor ............................................ 2 – 32
15 Right Motor, Armature Over-current .......................................... 2 – 34
16 Right Motor, Stall Timer ................................................................. 2 – 36
17 Right Motor, Faulty Field Circuit ................................................. 2 – 38
18 Right Motor, Faulty Field Drive .................................................... 2 – 40
19 Right Motor, Field Over-current ................................................... 2 – 42
20 Left Motor, Faulty Armature Circuit ............................................ 2 – 44
21 Left Motor, Transistor Wire Breakage ........................................ 2 – 47
22 Left Motor, Shorted Transistor ..................................................... 2 – 49
23 Left Motor, Faulty Transistor Drive ............................................. 2 – 51
24 Left Motor, Faulty Current Sensor .............................................. 2 – 53
25 Left Motor, Armature Over-current ............................................. 2 – 55
26 Left Motor, Stall Timer .................................................................... 2 – 57
27 Left Motor, Faulty Field Circuit .................................................... 2 – 59
28 Left Motor, Faulty Field Drive ....................................................... 2 – 61
29 Left Motor, Field Over-current ..................................................... 2 – 63
30 Pump Motor, Faulty Circuit ........................................................... 2 – 65
31 Pump Motor, Transistor Wire Breakage .................................... 2 – 68
32 Pump Motor, Shorted Transistor ................................................. 2 – 70
33 Pump Motor, Faulty Transistor Drive ......................................... 2 – 72
34 Pump Motor, Faulty Current Sensor .......................................... 2 – 74
35 Pump Motor, Armature Over-current ......................................... 2 – 76
40 Line Contactor, Abnormality ......................................................... 2 – 78
41 Regeneration Contactor, Abnormality ....................................... 2 – 80
43 Regeneration Diode, Abnormality ............................................... 2 – 82
44 Right Armature Diode, Abnormality ........................................... 2 – 84
45 Left Armature Diode, Abnormality .............................................. 2 – 86
46 Pump Armature Diode, Abnormality .......................................... 2 – 88
47 Right Motor, Wire Breakage ......................................................... 2 – 90
48 Left Motor, Wire Breakage ............................................................ 2 – 92
49 Pump Motor, Wire Breakage ........................................................ 2 – 94
51 Accelerator, Abnormality ............................................................... 2 – 96
52 Right Vehicle Speed Sensor, Abnormality ................................ 2 – 98
53 Left Vehicle Speed Sensor, Abnormality ................................... 2 – 100
54 FC Lever, Abnormality .................................................................... 2 – 102
55 FC Solenoid, Abnormality ............................................................. 2 – 104
57 FC Controller, Abnormality ........................................................... 2 – 106
E Direction Lever and Accelerator, Faulty Setting ..................... 2 – 108
(E) Seat Switch, Faulty Setting .......................................................... 2 – 110
H1 Lift Lever, Faulty Setting ............................................................... 2 – 112
H2 Tilt Lever, Faulty Setting ............................................................... 2 – 114
H3 Attachment 1 Lever, Faulty Setting ........................................... 2 – 116
H4 Attachment 2 Lever, Faulty Setting ........................................... 2 – 118
H5 FC Controller Lever, Faulty Setting ............................................ 2 – 120
60 Data Communication, Abnormality ............................................ 2 – 122
61 EEPROM, Abnormality ................................................................... 2 – 124
65 Logic Card, Faulty Initial Setting ................................................. 2 – 125
66 Controller, Abnormality .................................................................. 2 – 126
68 Battery Voltage,Excessively Low
(For 48-V Vehicles Only) ................................................................ 2 – 127
80 Steering Sensor, Abnormality ...................................................... 2 – 129
Electrical Schematic (DC motor models FC) .................................. 2 – 131
Electrical Schematic (DC motor models MC) ................................. 2 – 133
NOTE
For your reference, most pages are provided with
schematics of pertinent electrical circuits. Before
conducting troubleshooting, read the procedures
carefully and also refer to the Electrical Schematics.
General Information
Before replacing boards

Do not replace boards immediately even if replacement is required as a result of troubleshooting. Be sure to check
the following items before replacing boards (logic card, drive board and H bridge board).
• Loose battery connector
• Abnormal harness conditions
• Loose connectors
• Broken, bent or loose connector pins
• Dirty connectors
If contacts are dirty, remove the connector and clean the contacts.
See “How to clean harness connectors and system components” on page 2-2.
If any of the items listed above are a source of the problem, the board will be damaged even if it is replaced with a
new one. Be sure to check the above items and carefully replace.
2-1
How to clean harness connectors and system

components
1. Open-circuits are often caused by dirty harness
connectors and components. Dust, together with greasy
matter, forms grime which, in time, penetrates electrical
connections, resulting in loose metal-to-metal contact
or, for worse, electrical separation of surfaces in
contact. For this reason, it is essential that the
connectors and components be cleaned at each periodic
inspection and at when servicing the truck. Instead of a
commonly used solvent, use electronic parts cleaner (in
the manner illustrated on the right).
Electronic parts Three Bond 29D or

cleaner Pow-R-Wash CZ* 205046
NOTE
The cleaner liquid is volatile. All you have to do is just
give a strong spray to wash off grime.
No need to wipe off the sprayed liquid.
2. After checking the connector for continuity, wash it as

shown. Then, uncouple the connector and spray contact
surface activator onto contact surfaces. Install and
remove the connector several times to wet the surfaces
thoroughly with the activator liquid. After coupling up Electronic parts
cleaner
the connector, check to be sure that it is in locked state.
Contact surface Three Bond 2501S (aerosol)

activator or Nyogel 760G*
NOTE
Do not spray too much liquid into the connector.
Cleaner liquid reacts differently with some resins
(plastic materials).
*: Products contained in Terminal Maintenance Kit

(SE000003).
Contact surface
activator
205047
2-2
Item Alarm Detection Method/Condition Detecting Location

in Logic Card
Thermal switch signal input for right motor
E0 Right Motor, Overheating CN1-26
[150°C (302°F)]
Thermal switch signal input for left motor
E1 Left Motor, Overheating CN1-28
[150°C (302°F)]
Thermal switch signal input for pump motor
E2 Pump Motor, Overheating CN1-30
[150°C (302°F)]
Thermal sensor signal input for controller
E3 Controller, Overheating CN2-43
[80°C (176°F) thermistor]
E4 Right Motor, Worn Brushes Brush wear signal input for right motor CN1-27
E5 Left Motor, Worn Brushes Brush wear signal input for left motor CN1-29
E6 Pump Motor, Worn Brushes Brush wear signal input for pump motor CN1-31
Brake Oil, Low Level Level sensor signal input for brake oil (CN1-32)
Right Motor, Faulty Armature Combination from

10 Armature error under various conditions
Circuit CN2-34, 39, 41, 45
Right Motor, Transistor Wire Combination from
11 Armature error under ARM output ON
Breakage CN2-34, 39, 41, 45
Combination from
12 Right Motor, Shorted Transistor Armature error under ARM output OFF
CN2-34, 39, 41, 45
Right Motor, Faulty Transistor Abnormal over-current for right IGBT of drive
13 CN2-30 is less than 1 V
Drive board
Right Motor, Faulty Current Right current sensor error under ARM output Combination from
14
Sensor OFF CN2-34, 39, 41, 45
15 Right Motor, Armature Over-current Right motor armature current is 350 A or more CN2-45 is 2.45 V or more
16 Right Motor, Stall Timer The time set with setup option elapsed
Combination from
17 Right Motor, Faulty Field Circuit Error in line voltage or field current
CN2-15, 34
H bridge board detected abnormal over current
18 Right Motor, Faulty Field Drive CN2-13 is less than 1 V
for right FET
Right motor field over-current is 45 A or more
19 Right Motor, Field Over-current CN2-15 is 4.5 V or more
(continues 5 msec)
Combination from
20 Left Motor, Faulty Armature Circuit Armature error under various conditions
CN2-34, 39, 42, 47
Combination from
21 Left Motor, Transistor Wire Breakage Armature error under ARM output ON
CN2-34, 39, 42, 47
Combination from
22 Left Motor, Shorted Transistor Armature error under ARM output OFF
CN2-34, 39, 42, 47
23 Left Motor, Faulty Transistor Drive Abnoromal detection signal from drive board CN2-31 is less than 1 V
Combination from
24 Left Motor, Faulty Current Sensor Left current sensor error under ARM output OFF
CN2-34, 39, 42, 47
25 Left Motor, Armature Over-current Left motor armature current is 350 A or more CN2-47 is 2.45 V or more
26 Left Motor, Stall Timer The time set with setup option elapsed
27 Left Motor, Faulty Field Circuit Error in line voltage or field current Combination from CN2-17, 34
H bridge board detected abnormal over-current
28 Left Motor, Faulty Field Drive CN2-14 is less than 1 V
for left FET
Left motor field over-current is 45 A or more
29 Left Motor, Field Over-current CN2-17 is 4.5 V or more
(continues 5 msec)
Checks voltage level and current level for Combination from
30 Pump Motor, Faulty Circuit
main circuit CN2-34, 39, 40, 49
Pump Motor, Transistor Wire Checks voltage level and current level for Combination from
31
Breakage main circuit CN2-34, 39, 40, 49
Checks voltage level and current level for Combination from
32 Pump Motor, Shorted Transistor
main circuit CN2-34, 39, 40, 49
33 Pump Motor, Faulty Transistor Drive Abnormal detection signal from drive board CN2-32 is less than 1 V
2-5
Item Alarm Detection Method/Condition Detecting Location

in Logic Card
Combination from
34 Pump Motor, Faulty Current Sensor Checks current sensor output
CN2-34, 39, 40, 49
35 Pump Motor, Armature Over-current Pump motor current is 450 A or more CN2-49 is 3.15 V or more
Contactor over-current
40 Line Contactor, Abnormality Contactor error under line contactor ON
(/EERR3)
Contactor error under traction and regeneration Contactor over-current
41 Regeneration Contactor, Abnormaliity
output (/EERR3)
Combination from
43 Regeneration Diode, Abnormality Error during traction
CN2-34, 39, 41, 42, 45, 47
Combination from
44 Right Armature Diode, Abnormality Armature error under ARM output ON
CN2-34, 39, 41, 45
Combination from
45 Left Armature Diode, Abnormality Armature error under ARM output ON
CN2-34, 39, 42, 47
Checks voltage level and current level for main Combination from
46 Pump Armature Diode, Abnormality
circuit CN2-34, 39, 40, 49
Combination from
47 Right Motor, Wire Breakage Error under ARM output OFF during regeneration
CN2-34, 39, 41, 45
Combination from
48 Left Motor, Wire Breakage Error under ARM output OFF during regeneration
CN2-34, 39, 42, 47
Checks voltage level and current level for main Combination from
49 Pump Motor, Wire Breakage
circuit CN2-34, 39, 40, 49
51 Accelerator, Abnormality Out of input range CN1-33
Right Vehicle Speed Sensor,
52 Wire breakage or short circuit CN1-43, 45 (/ERR1)
Abnormality
Left Vehicle Speed Sensor,
53 Wire breakage or short circuit CN1-47, 49 (/ERR3)
Abnormality
54 FC Lever Abnormality Abnormal signal from FC controller
55 FC Solenoid, Abnormality Abnormal signal from FC controller
57 FC Controller, Abnormality Abnormal signal from FC controller
Direction Lever and Accelerator, Lever is not in neutral or accelerator is not

E
Faulty Setting “0” when power is turned on
(E) Seat Switch, Faulty Setting No signal input when power is turned on CN1-9
H1 Lift Lever, Faulty Setting Signal input when power is turned on CN1-16, 17
H2 Tilt Lever, Faulty Setting Signal input when power is turned on CN1-18
H3 Attachment 1 Lever, Faulty Setting Signal input when power is turned on CN1-19
H4 Attachment 2 Lever, Faulty Setting Signal input when power is turned on CN1-20
H5 FC Controller Lever, Faulty Setting Abnormal signal from FC controller
Display unit shows undefined characters during Logic power supply failure or
60 Data Communication, Abnormality
no communication made CN1-59, 61
Executes parity check for SUO data when power
61 EEPROM, Abnormality
is turned on
Incorrect DSW setting (no setting for truck speed
65 Logic Card, Faulty Initial Setting
selection)
66 Controller, Abnormality ROM/RAM check when power is turned on
Voltage is less than 42 V when power is turned on
68 Battery Voltage, Excessively Low CN2-33
(48 V truck)
Voltage is more than 42 V when power is turned
69 Battery Voltage, Excessively High CN2-33
on (36 V truck)
Battery volgate is between 22 V to 25 V during
Battery Voltage, Low CN2-33
truck operation
Each voltage is less than 22 V when line contactor
(L0) (Battery Voltage, Low) CN2-34, 39, 40, 41, 42
ON
80 Steering Sensor, Abnormality Signal input when power is turned on
2-6
Problem: Right Motor, Overheating (E0)

Indication: Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor and
power steering operations. (Activation of right traction motor thermal switch)
(1) Situation
Indication: Controller/motor overheat indicator ON ("E0" stored in history folder, but not displayed).
Poor pulling power and acceleration. Normal pump motor and power steering operations.
(2) Possible cause

Overheating of right traction motor, abnormality or wire break in right traction motor thermal switch (temperature
sensor), faulty logic card.
(3) How the error code is triggered

Right motor temperature is over 150 C (302 F).
Software checks following signal and detects fault when the signal is longer than 200 ms.
Traction Motor Right Thermal SW. (CN1-26)
(4) Checks
Let vehicle cool for 15 minutes.
Overheat indicator ON Normal indication
(5) Disconnect battery plug. Wait until right traction motor (12) Operate vehicle and check for overheating of right trac-
temperature becomes close to room temperature. tion motor. If problem reoccurs, check the following:
Disconnect right traction motor thermal switch. Check Operating cycle for excessive ramp climbing, towing
thermal switch continuity. There should be electric and pushing.
continuity below 150 C (302 F). Brake drag, parking brake adjustment and brake
Continuity No continuity switch operation.
(6) Check continuity between wire 124G (Green) of (11) Replace thermal switch.
thermal switch harness connector and NEG.
Continuity No continuity
(7) Remove logic card cover. Check continuity between (10) Correct or replace wiring.
motor sensor 125Y (Yellow) and logic card CN1-26,
and shorting of these terminals with NEG.
Continuity, No continuity,
no shorting or shorted
(8) Faulty logic card (9) Correct or replace wiring.
2-7
211468
2-8
Problem: Left Motor, Overheating (E1)

Indication: Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor and
power steering operations. (Activation of left traction motor thermal switch)
(1) Situation
(2) Possible cause

Overheating of left traction motor, abnormality or wire break in left traction motor thermal switch (temperature

Left motor temperature is over 150 C (302 F).
Traction Motor Left Thermal SW. (CN1-28)
(4) Checks
(5) Disconnect battery plug. Wait until left traction motor (12) Operate vehicle and check for overheating of left trac-
temperature becomes close to room temperature. tion motor. If problem reoccurs, check the following:
Disconnect left traction motor thermal switch. Check Operating cycle for excessive ramp climbing, towing
thermal switch continuity. There should be electric and pushing.
continuity below 150 C (302 F). Brake drag, parking brake adjustment and brake
Continuity No continuity switch operation.
(6) Check continuity between wire 129G (Green) of (11) Replace thermal switch.
motor sensor 130Y (Yellow) and logic card CN1-28,
2-9
211469
2-10
Problem: Pump Motor, Overheating (E2)

Indication: Controller/motor overheat indicator ON. Pump motor lifting speed slower than normal. Normal traction
motor and power steering operations. (Activation of pump motor thermal switch)
(1) Situation
Pump motor lifting speed slower than normal. Normal traction motor and power steering operations.
(2) Possible cause

Overheating of pump motor, abnormality or wire break in pump motor thermal switch (temperature

Pump motor temperature is over 150 C (302 F).
Pump Motor Thermal SW. (CN1-30)
(4) Checks
(5) Disconnect battery plug. Wait until pump motor (12) Operate vehicle and check for overheating of pump
temperature becomes close to room temperature. motor. If problem reoccurs, check the following:
Disconnect pump motor thermal switch. Check Operating cycle for excessive hydraulic load (heavy
thermal switch continuity. There should be electric load lifting).
continuity below 150 C (302 F).
(6) Check continuity between wire 134W (White) of (11) Replace thermal switch.
motor sensor 135R (Red) and logic card CN1-30,
2-11
211470
2-12
Problem: Controller, Overheating (E3)

Indication: Controller/motor overheat indicator ON. Poor pulling power and acceleration. Pump motor lifting speed
slower than normal. Normal power steering operation. (Controller thermal control activation)
(1) Situation
Indication: Controller/motor overheat indicator ON ("E3" stored in history folder, but not displayed). Poor pulling
power and acceleration. Pump motor lifting speed slower than normal. Normal power steering operation.
(2) Possible cause

Overheating of controller panel, abnormality or wire break in controller thermistor (temperature sensor),
faulty logic card.

Controller panel temperature is over 80 C (176 F).
Software checks following signal and detects fault.
Controller Thermo. (CN2-43)
(4) Checks
(5) Disconnect battery plug. Wain until controller (12) Operate vehicle and check for overheating of
temperature comes close to room temperature. controller. If problem reoccurs, check power supply to
Disconnect controller termistor connector. Measure traction and pump motors or operating cycle. Also,
thermistor resistance. Measured resistance should be check if vehicle is operated on steep upgrade or to
8 k or higher at temperature below 70°C (158°F). pull or lift large cago load.
(6) Check continuity between temperature sensor (11) Replace thermal switch.
connector B (Black) and NEG.
logic card CN2-43BrR (Brown, Red) and temperature
sensor connector BrR (Brown, Red).
2-13
211471
2-14
Problem: Right Motor, Worn Brushes (E4)

Indication: Worn brush indicator ON. Poor pulling power and acceleration. Normal pump motor and power steering
operations.
(1) Situation
Indication: Worn brush indicator ON ("E4" stored in history folder, but not displayed).
(2) Possible cause

Worn right motor brushes, short circuit, faulty indication, faulty logic card.

Right motor brush is worn and signal becomes 0 V (GND).
Traction Motor Right Brush SW. (CN1-27)
(4) Checks
Disconnect battery plug. Disconnect brush wear detector wires 126-V (Purple) and 127-O (Orange) from right
traction motor. Reconnect battery plug, and close key switch. Check to see if indicator turns OFF.
Indicator ON Indicator OFF
(5) Disconnect battery plug. Check continuity in brush (8) Check brushes and replace, if necessary.
wear detector wires. With wires and connectors
disconnected, also check shorting between positive (+)
and negative (-) sides of batteries.
Controller CN1-27W (White) - Right motor
126-V (Purple)/127-O (Orange)
(6) Replace logic card. (7) Correct or replace wiring.
2-15
211468
2-16
Problem: Left Motor, Worn Brushes (E5)

Indication: Worn brush indicator ON. Poor pulling power and acceleration. Normal pump motor and power steering
operations.
(1) Situation
Indication: Worn brush indicator ON ("E5" stored in history folder, but not displayed).
(2) Possible cause

Worn left motor brushes, short circuit, faulty indication, faulty logic card.

Left motor brush is worn and signal becomes 0 V (GND).
Traction Motor Left Brush SW. (CN1-29)
(4) Checks
Disconnect battery plug. Disconnect brush wear detector wires 131-V (Purple) and 132-O (Orange) from left
traction motor. Reconnect battery plug, and close key switch. Check to see if indicator turns OFF.
Controller CN1-29L (Blue) - Left motor
131-V (Purple)/132-O (Orange)
2-17
211469
2-18
Problem: Pump Motor, Worn Brushes (E6)

Indication: Worn brush indicator ON. Pump motor lifting speed slower than normal. Normal traction motor and
power steering operations.
(1) Situation
Indication: Worn brush indicator ON ("E6" stored in history folder, but not displayed). Pump motor
lifting speed slower than normal. Normal traction motor and power steering operations.
(2) Possible cause

Worn pump motor brushes, short circuit, faulty indication, faulty logic card.

Pump motor brush is worn and signal becomes 0 V (GND).
Pump Motor Brush SW. (CN1-31)
(4) Checks
Disconnect battery plug. Disconnect brush wear detector wires 136-R (Red) and 137-Y (Yellow) from pump
motor. Reconnect battery plug, and close key switch. Check to see if indicator turns OFF.
Controller CN1-31V (Purple) - Pump motor
136-R (Red)/137-Y (Yellow)
2-19
211470
2-20
Problem: Brake Oil, Low Level

Indication: Low brake oil indicator ON. Normal vehicle operation.
(1) Situation
Indication: Low brake oil indicator ON. Normal vehicle operation.
(2) Possible cause

Insufficient brake oil, wire breakage, faulty indication, faulty logic card.

Software checks following signal and detects fault.
Brake Fluid Sensor SW. (CN1-32)
(4) Checks
Check oil level in brake oil reservoir tank.
Oil level higher than LOW mark Oil level lower than LOW mark
(5) Disconnect battery plug. Disconnect level sensor (10) Add brake oil.
connector CN10, and check continuity.
No continuity Continuity
(9) Replace level sensor.
(6) With connector CN10 disconnected, check continuity

between harness connector socket wire 140L(Blue)
and NEG, and between 139O (Orange) and controller
CN1-32.
2-21
211472
2-22
Problem: Right Motor, Faulty Armature Circuit (10)

Indication: “10” display. Vehicle operation (traction and pump motors) disabled.
(1) Situation
Indication: "10" display. Vehicle operation disabled.
(2) Possible cause

Faulty right motor armature circuit, faulty line contactor, faulty regeneration contactor, faulty D1R diode, faulty D2
diode, faulty right motor armature wiring, faulty head capacitor, faulty T1R IGBT, faulty CS1 current sensor, faulty
wiring in other parts, faulty logic card, faulty drive board, faulty H bridge board.

Right motor armature fault is detected.
Software checks following signals and detects fault.
Pump Motor Voltage (CN2-34) R. Tr. Voltage (CN2-41)
L. & R. Armature Voltage (CN2-39) R. Armature Current (CN2-45)
(4) Checks
Disconnect battery plug. Check line and regeneration contactor tips for wire breakage and melting. Make sure each
contactor tip moves freely. See page 1-37.
No broken or shorted wire Broken or shorted wire
(5)Check right motor armature wiring for wire breakage (18) Correct or replace faulty components (regeneration
and shorting. See page 3-15. contactor, line contactor).
No broken or Broken or
shorted wire shorted wire
(6) Check T1R IGBT, D1R diode, D2 diode and head (17) Correct or replace right motor, or correct or replace
capacitor for abnormality. Check wiring between D1R wiring.
and logic card for abnormality.
See pages 1-46, 1-43 and 1-35.
Acceptable Unacceptable
(7) Check drive board. Check wiring between T1R and (16) Replace faulty components (T1R, D1R, D2, head
drive board for abnormality. See pages 1-44 to 1-48. capacitor) or wiring.
(8) Check H bridge board. Check wiring between drive (15) Replace drive board or wiring.
motor (R) and H bridge board, and wiring between
POS/NEG and H bridge board for abnormality.
See pages 1-48 to 1-51.
2-23
(9) Check CS1 current sensor for abnormality. Check (14) Replace H bridge board or wiring.
wiring between CS1 and logic card for abnormality.
See page 1-37.
(10)Check logic card, connector and wiring for abnormality. (13) Replace CS1 current sensor or wiring.
Wiring acceptable Wiring unacceptable
(11) Replace logic card. (12) Clean connector or correct wiring, or replace logic
card or wiring.
2-24
211473
2-25
Problem: Right Motor, Transistor Wire Breakage (11)

(1) Situation
(2) Possible cause

Wire break in T1R, faulty drive board, faulty CS1 current sensor, faulty logic card, faulty wiring.

Right motor transistor opens when armature voltage output is on.
(4) Checks
Check T1R for abnormality. See page 1-46.
(5)Check drive board. Check wiring between T1R and (12) Replace faulty component (T1R).
drive board for abnormality. See pages 1-44 to 1-48.
(6) Check CS1 for abnormality. Check wiring between (11) Replace drive board or wiring.
CS1 and logic card for abnormality. See page 1-37.
(7) Check logic card, connector and wiring for abnormality. (10) Replace CS1 current sensor or wiring.
(8)Replace logic card. (9) Clean connector or

correct wiring, or replace
logic card or wiring.
2-26
211473
2-27
Problem: Right Motor, Shorted Transistor (12)

(1) Situation
(2) Possible cause

Shorting in T1R, faulty drive board, faulty CS1 current sensor, faulty logic card, faulty wiring.

Right motor transistor shorts when armature voltage output is off.
(4) Checks
Check T1R for abnormality. See page 1-46.
(5)Check drive board. See pages 1-44 to 1-48. (12) Replace faulty component (T1R).
(6) Check CS1 for abnormality. Check wiring between (11) Replace drive board.

2-28
211473
2-29
Problem: Right Motor, Faulty Transistor Drive (13)

(1) Situation
(2) Possible cause

Wire break in T1R, faulty drive board, faulty CS1 current sensor, faulty logic card, faulty wiring.

When right IGBT detects over-current.
Software checks following signal and detects fault when the signal is under 1V.
R. Armature Error (CN2-30)
(4) Checks
Disconnect battery plug. Check T1R for abnormality. See page 1-46.
(5)Check drive board. Check wiring between drive board (12) Replace faulty component (T1R).
and logic card, and between drive board and T1R for
abnormality. See pages 1-44 to 1-48.
(6) Check CS1 current sensor for abnormality. Check (11) Replace drive board or wiring.
See page 1-37.

2-30
211474
2-31
Problem: Right Motor, Faulty Current Sensor (14)

(1) Situation
(2) Possible cause

Faulty CS1 current sensor, faulty wiring, faulty logic card.

Right armature current sensor is detected when armature voltage output is off and right current sensor is faulty.
(4) Checks
Check CS1 current sensor. See page 1-37.
(5) Check logic card, connector and wiring for abnormality. (8) Replace CS1 current sensor.

2-32
211473
2-33
Problem: Right Motor, Armature Over-current (15)

(1) Situation
(2) Possible cause


When right armature current is over 350A.
Software checks following signal and detects fault when the signal is over 2.45V.
R. Armature Current (CN2-45)
(4) Checks
Disconnect battery plug. Check regeneration and line contactor tips for melting (shorting). Make sure each contactor
tip moves freely. See page 1-37.
No shorted wire Shorted wire
(5) Check CS1 current sensor. See page 1-37. (11) Correct or replace faulty contactors.
(6) Replace output T1R IGBT. See page 1-61. (10) Replace CS1 current sensor.
(7) If replacement of output IGBT does not correct

problem, check logic card, connector and wiring for
(8) Replace logic card. (9) Clean connector or

2-34
211475
2-35
Problem: Right Motor, Stall Timer (16)

(1) Situation
(2) Possible cause

Stall current flowed more than set time in right traction motor. Faulty CS1 current sensor, faulty wiring,
faulty logic card.

Stall timer set time (set by Setup Option #20) is measured during stalling.
(4) Checks
Check to see if vehicle is operated on steep upgrade or to pull large cargo load when motor stalls.
Operated under normal condition Operated under heavy load
(5) Check CS1 current sensor. Check wiring between CS1 (10) Do not operate vehicle for more than set time under a
and logic card for abnormality. See page 1-37. condition that causes motor to stall.
Acceptable Unacceptable If necessary, adjust Setup Option #20.
(6) Check logic card, connector and wiring for (9) Replace CS1 current sensor, or correct or replace
abnormality. See pages 1-28 to 1-34. wiring.
(7) Replace logic card. (8) Clean connector or correct wiring, or replace
2-36
211475
2-37
Problem: Right Motor, Faulty Field Circuit (17)

Indication: “17” display. Vehicle operation disabled.
(1) Situation
(2) Possible cause

Faulty right motor field circuit (wire breakage, shorting), faulty logic card.

Right motor field fault is detected.
R. Field Current (CN2-15) Pump Motor Voltage (CN2-34)
(4) Checks
Disconnect battery plug. Check H bridge board for abnormality. See pages 1-48 to 1-51.
(5) Check logic card, connector and wiring for abnormality. (8) Replace H bridge board.

2-38
211476
2-39
Problem: Right Motor, Faulty Field Drive (18)

(1) Situation
(2) Possible cause

Faulty right motor field circuit, faulty H bridge board, faulty logic card, faulty controller harness.

When H bridge board detects over-current for right FET.
R. Field Error (CN2-13)
(4) Checks
Disconnect battery plug. Check right motor field cable terminals, logic card CN2-13 terminal and H bridge board
CN2-16 terminal for abnormality.
(5) Check continuity between following terminals. (11) Correct or replace cables.
Right motor field cables
Logic card CN2-13 and CN2-63 (NEG)
No shorted Shorted
(6) Turn on key switch and confirm "18" is displayed. (10) Correct or replace faulty circuit.
(7) Confirm voltage between CN2-13 and CN2-63 (NEG)

with multi-meter.
About 0V About 15V
(8) Replace H bridge board. (9) Replace logic card.
2-40
211477
2-41
Problem: Right Motor, Field Over-current (19)

(1) Situation
(2) Possible cause

Faulty right motor field circuit, faulty logic card.

Software checks following signal and detects fault when the signal (over 4.5V) keeps more than 5 ms.
R. Field Current (CN2-15)
(4) Checks
Disconnect battery plug. Check H bridge board for abnormality. See page 1-48.
(5) Check right motor field wiring for abnormality. (8) Replace H bridge board.
See page 3-15.
Unacceptable Acceptable
(6) Replace right motor field wiring. (7) Replace logic card.
2-42
211478
2-43
Problem: Left Motor, Faulty Armature Circuit (20)

(1) Situation
(2) Possible cause

Faulty left motor armature circuit, faulty line contactor, faulty regeneration contactor, faulty D1L diode, faulty D2
diode, faulty left motor armature wiring, faulty head capacitor, faulty T1L IGBT, faulty CS2 current sensor, faulty
wiring in other parts, faulty logic card, faulty drive board, faulty H bridge board.

Left motor armature fault is detected.
Pump Motor Voltage (CN2-34) L. Tr. Voltage (CN2-42)
L. & R. Armature Voltage (CN2-39) L. Armature Current (CN2-47)
(4) Checks
(5)Check left motor armature wiring for wire breakage (18) Correct or replace faulty components (regeneration
and shorting. See page 3-15. contactor, line contactor).
(6) Check T1L IGBT, D1L diode, D2 diode and head (17) Correct or replace left motor, or correct or replace
capacitor for abnormality. Check wiring between D1L wiring.
and logic card for abnormality.
See pages 1-46, 1-43 and 1-35.
(7) Check drive board. Check wiring between T1L and (16) Replace faulty components (T1L, D1L, D2, head
(8) Check H bridge board. Check wiring between drive (15) Replace drive board or wiring.
motor (L) and H bridge board, and wiring between
POS/NEG and H bridge board for abnormality.
2-44
(9) Check CS2 current sensor for abnormality. Check (14) Replace H bridge board or wiring.
See page 1-39.
card or wiring.
2-45
211479
2-46
Problem: Left Motor, Transistor Wire Breakage (21)

(1) Situation
(2) Possible cause

Wire break in T1L, faulty drive board, faulty CS2 current sensor, faulty logic card, faulty wiring.

Left motor transistor opens when armature voltage output is on.
(4) Checks
Check T1L for abnormality. See page 1-46.
(5)Check drive board. Check wiring between T1L and (12) Replace faulty component (T1L).

2-47
211479
2-48
Problem: Left Motor, Shorted Transistor (22)

(1) Situation
(2) Possible cause

Shorting in T1L, faulty drive board, faulty CS2 current sensor, faulty logic card, faulty wiring.

Left motor transistor shorts when armature voltage output is off.
(4) Checks
Check T1L for abnormality. See page 1-46.
(5)Check drive board. See pages 1-44 to 1-48. (12) Replace faulty component (T1L).

2-49
211479
2-50
Problem: Left Motor, Faulty Transistor Drive (23)

(1) Situation
(2) Possible cause

Wire break in T1L, faulty drive board, faulty CS2 current sensor, faulty logic card, faulty wiring.

When left IGBT detects over-current.
L. Armature Error (CN2-31)
(4) Checks
Disconnect battery plug. Check T1L for abnormality. See page 1-46.
(5)Check drive board. Check wiring between drive board (12) Replace faulty component (T1L).
and logic card, and between drive board and T1L for
See page 1-39.

2-51
211480
2-52
Problem: Left Motor, Faulty Current Sensor (24)

(1) Situation
(2) Possible cause


Left armature current sensor is detected when armature voltage output is off and left current sensor is faulty.
(4) Checks

2-53
211479
2-54
Problem: Left Motor, Armature Over-current (25)

(1) Situation
(2) Possible cause


When left armature current is over 350A.
Software checks following signal and detects fault when the signal is over 2.45V.
L. Armature Current (CN2-47)
(4) Checks
(6) Replace output T1L IGBT. See page 1-61. (10) Replace CS2 current sensor.
(7) If replacement of output IGBT does not correct

problem, check logic card, connector and wiring for
(8) Replace logic card. (9) Clean connector or

2-55
211481
2-56
Problem: Left Motor, Stall Timer (26)

(1) Situation
(2) Possible cause

Stall current flowed more than set time in left traction motor. Faulty CS2 current sensor, faulty wiring,
faulty logic card.

Stall timer set time (set by Setup Option #20) is measured during stalling.
(4) Checks
Check to see if vehicle is operated on steep upgrade or to pull large cargo load when motor stalls.
Operated under normal condition Operated under heavy load
(5) Check CS2 current sensor. Check wiring between CS2 (10) Do not operate vehicle for more than set time under a
and logic card for abnormality. See page 1-39. condition that causes motor to stall.
Acceptable Unacceptable If necessary, adjust Setup Option #20.
(6) Check logic card, connector and wiring for (9) Replace CS2 current sensor, or correct or replace
abnormality. See pages 1-28 to 1-34. wiring.
(7) Replace logic card. (8) Clean connector or correct wiring, or replace
2-57
211481
2-58
Problem: Left Motor, Faulty Field Circuit (27)

(1) Situation
(2) Possible cause

Faulty left motor field circuit (wire breakage, shorting), faulty logic card.

Left motor field fault is detected.
L. Field Current (CN2-17) Pump Motor Voltage (CN2-34)
(4) Checks
Disconnect battery plug. Check H bridge board for abnormality. See pages 1-48 to 1-51.
(5) Check logic card, connector and wiring for abnormality. (8) Replace H bridge board.

2-59
211482
2-60
Problem: Left Motor, Faulty Field Drive (28)

(1) Situation
(2) Possible cause

Faulty left motor field circuit, faulty H bridge board, faulty logic card, faulty controller harness.

When H bridge board detects over-current for left FET.
L. Field Error (CN2-14)
(4) Checks
Disconnect battery plug. Check left motor field cable terminals, logic card CN2-14 terminal and H bridge board
CN2-15 terminal for abnormality.
(5) Check continuity between following terminals. (11) Correct or replace cables.
Left motor field cables
Logic card CN2-14 and CN2-63 (NEG)
No shorted Shorted
(10) Correct or replace faulty circuit.

(6) Turn on key switch and confirm "28" is displayed.
(7) Confirm voltage between CN2-14 and CN2-63 (NEG)

with multi-meter.
About 0V About 15V
(8) Replace H bridge board. (9) Replace logic card.
2-61
211483
2-62
Problem: Left Motor, Field Over-current (29)

(1) Situation
(2) Possible cause

Faulty left motor field circuit, faulty logic card.

Software checks following signal and detects fault when the signal (over 4.5V) keeps more than 5 ms.
L. Field Current (CN2-17)
(4) Checks
Disconnect battery plug. Check H bridge board for abnormality. See page 1-48.
(5) Check left motor field wiring for abnormality. (8) Replace H bridge board.
See page 3-15.
Unacceptable Acceptable
(6) Replace left motor field wiring. (7) Replace logic card.
2-63
211484
2-64
Problem: Pump Motor, Faulty Circuit (30)

(1) Situation
(2) Possible cause

Faulty pump motor circuit, faulty line contactor, faulty regeneration contactor, faulty D1P diode, faulty pump motor
wiring, faulty head capacitor, faulty T1P IGBT, faulty CS3 current sensor, faulty wiring in other parts, faulty logic
card, faulty drive board.

Pump Motor Voltage (CN2-34) Pump Tr. Voltage (CN2-40)
L. & R. Armature Voltage (CN2-39) Pump Current (CN2-49)
(4) Checks
(5)Check pump motor wiring for wire breakage (16) Correct or replace faulty components (regeneration
and shorting. See page 3-15. contactor or line contactor).
(6) Check T1P IGBT, D1P diode and head capacitor for (15) Correct or replace pump motor, or correct or replace
abnormality. Check wiring between D1P and logic wiring.
card for abnormality.
See pages 1-46, 1-43 and 1-35.
(7) Check drive board. Check wiring between T1P and (14) Replace faulty components (T1P, D1P, head
See page 1-41.
2-65
card or wiring.
2-66
211485
2-67
Problem: Pump Motor, Transistor Wire Breakage (31)

(1) Situation
(2) Possible cause

Wire break in T1P, faulty pump motor drive board, faulty CS3 current sensor, faulty logic card, faulty wiring.

Software checks following signals and detects fault when pump motor rotates.
(4) Checks
Check T1P for abnormality. See page 1-46.
(5)Check drive board. Check wiring between T1P and (12) Replace faulty component (T1P).

2-68
211485
2-69
Problem: Pump Motor, Shorted Transistor (32)

(1) Situation
(2) Possible cause

Shorting in T1P, faulty pump motor drive board, faulty CS3 current sensor, faulty logic card, faulty wiring.

Software checks following signals and detects fault when line contactor closes and pump motor does not rotate.
(4) Checks
Check T1P for abnormality. See page 1-46.
(5)Check drive board. See pages 1-44 to 1-48. (12) Replace faulty component (T1P).

2-70
211485
2-71
Problem: Pump Motor, Faulty Transistor Drive (33)

Indication: “33” display. Vehicle operation (traction and pump motors) disabled..
(1) Situation
(2) Possible cause

Wire break in T1P, faulty drive board, faulty CS3 current sensor, faulty logic card, faulty wiring.

Software checks following signal and detects fault when line contactor closes.
Pump Error (CN2-32)
(4) Checks
Disconnect battery plug. Check T1P for abnormality. See page 1-46.
(5)Check drive board. Check wiring between drive board (12) Replace faulty component (T1P).
and logic card, and between drive board and T1P for
See page 1-41.

2-72
211486
2-73
Problem: Pump Motor, Faulty Current Sensor (34)

(1) Situation
(2) Possible cause


Software checks following signals and detects fault when line contactor closes and pump motor does not rotate.
(4) Checks

2-74
211485
2-75
Problem: Pump Motor, Armature Over-current (35)

(1) Situation
(2) Possible cause


Software checks following signal and detects fault during software running.
Pump Current (CN2-49)
Software detects fault when pump current (CN2-49) is more than 3.5V and it continues longer than 5 msec.
(4) Checks
(6) Check T1P IGBT. See page 1-46. (11) Replace CS3 current sensor.
(7) Check logic card, connector and wiring for abnormality. (10) Replace T1P IGBT.

2-76
211487
2-77
Problem: Line Contactor, Abnormality (40)

(1) Situation
(2) Possible cause

Faulty line contactor (wire breakage, shorting), faulty logic card.

Software checks following signals and detects fault when line contactor closes.
Pump Motor Voltage (CN2-34) L. Armature Current (CN2-47)
L. & R. Armature Voltage (CN2-39) R. Field Current (CN2-15)
R. Tr. Voltage (CN2-41) L. Field Current (CN2-17)
R. Armature Current (CN2-45) Pump Tr. Voltage (CN2-40)
L. Tr. Voltage (CN2-42) Pump Current (CN2-49)
(4) Checks
Disconnect battery plug. Check line contactor tip for wire breakage and shorting (melting).
Check that contactor tip moves freely. See page 1-37.
(5) Check logic card, connector and wiring for abnormality. (8) Correct or replace faulty component (line contactor).
card or wiring.
2-78
211488
2-79
Problem: Regeneration Contactor, Abnormality (41)

(1) Situation
(2) Possible cause

Faulty regeneration contactor (wire breakage, shorting), faulty logic card.

Pump Motor Voltage (CN2-34) R. Armature Current (CN2-45)
L. & R. Armature Voltage (CN2-39) L. Tr. Voltage (CN2-42)
R. Tr. Voltage (CN2-41) L. Armature Current (CN2-47)
(4) Checks
Disconnect battery plug. Check regeneration contactor tip for wire breakage and shorting (melting).
Check that contactor tip moves freely. See page 1-37.
(5) Check logic card, connector and wiring for abnormality. (8) Correct or replace faulty component (regeneration
See pages 1-28 to 1-34. contactor).
card or wiring.
2-80
211489
2-81
Problem: Regeneration Diode, Abnormality (43)

(1) Situation
(2) Possible cause

Faulty regeneration diode (wire breakage, shorting), faulty CS1/CS2 current sensor, faulty logic card.

Software checks following signals and detects fault while motor is powering.
R. Tr. Voltage (CN2-41) L. Armature Current (CN2-47)
(4) Checks
Disconnect battery plug. Check D2 regeneration diode for abnormality. See page 1-43.
(5)Check CS1 and CS2 current sensors for abnormality. (10) Replace faulty component (D2).
Check wiring between CS1 and T1R, and between CS2
and T1L. See pages 1-37 to 1-41.
(6) Check logic card, connector and wiring for abnormality. (9) Replace CS1 and/or CS2 current sensor or wiring.
card or wiring.
2-82
211490
2-83
Problem: Right Armature Diode, Abnormality (44)

(1) Situation
(2) Possible cause

Faulty right armature diode (wire breakage, shorting), faulty CS1 current sensor, faulty logic card.

(4) Checks
Disconnect battery plug. Check right armature diode D1R for abnormality.
See page 1-43.
(5) Check CS1 current sensor for abnormality. Check (10) Replace faulty component (D1R).
wiring between CS1 and D1R for abnormality.
See page 1-37.
card or wiring.
2-84
211473
2-85
Problem: Left Armature Diode, Abnormality (45)

(1) Situation
(2) Possible cause

Faulty left armature diode (wire breakage, shorting), faulty CS2 current sensor, faulty logic card.

(4) Checks
Disconnect battery plug. Check left armature diode D1L for abnormality.
See page 1-43.
(5) Check CS2 current sensor for abnormality. Check (10) Replace faulty component (D1L).
wiring between CS2 and D1L for abnormality.
See page 1-39.
(7)Replace logic card. (8) Clean connector or correct wiring, or replace logic
card or wiring.
2-86
211479
2-87
Problem: Pump Armature Diode, Abnormality (46)

(1) Situation
(2) Possible cause

Faulty pump armature diode (wire breakage, shorting), faulty CS3 current sensor, faulty logic card.

(4) Checks
Disconnect battery plug. Check pump armature diode D1P for abnormality.
See page 1-43.
(5) Check CS3 current sensor for abnormality. Check (10) Replace faulty component (D1P).
wiring between CS3 and D1P for abnormality.
See page 1-41.
card or wiring.
2-88
211485
2-89
Problem: Right Motor, Wire Breakage (47)

(1) Situation
(2) Possible cause

Wire breakage in right motor, faulty CS1 current sensor, faulty logic card.

Software checks following signals and detects fault during regeneration.
(4) Checks
Disconnect controller terminals A1R, A2R and field wiring connector (4pins), and check resistance between A1R
and A2R and between S1R and S2R.
Resistance detected Wire break
(5) Check CS1 current sensor for abnormality. Check (10) Replace right motor, or correct or replace right motor
wiring between A1R and A2R for abnormality. wiring.
See page 1-37.
card or wiring.
2-90
211491
2-91
Problem: Left Motor, Wire Breakage (48)

(1) Situation
(2) Possible cause

Wire breakage in left motor, faulty CS2 current sensor, faulty logic card.

Software checks following signals and detects fault during regeneration.
(4) Checks
Disconnect controller terminals A1L, A2L and field wiring connector (4pins), and check resistance between A1L
and A2L and between S1L and S2L.
(5) Check CS2 current sensor for abnormality. Check (10) Replace left motor, or correct or replace left motor
wiring between A1L and A2L for abnormality. wiring.
See page 1-39.
card or wiring.
2-92
211492
2-93
Problem: Pump Motor, Wire Breakage (49)

(1) Situation
(2) Possible cause

Wire breakage in pump motor, faulty CS3 current sensor, faulty logic card.

(4) Checks
Disconnect battery plug. Disconnect controller terminals PA1 and PS2, and check resistance between
PA1 and PS2.
(5) Check CS3 current sensor for abnormality. Check (10) Replace pump motor, or correct or replace pump
wiring between PA1 and PS2 for abnormality. motor wiring.
See page 1-41.
card or wiring.
2-94
211493
2-95
Problem: Accelerator, Abnormality (51)

Indication: “51” display. Faulty accelerator circuit. Traction and pump motors disabled.
(1) Situation
Indication: "51" display. Faulty accelerator circuit.
(2) Possible cause

Faulty accelerator, faulty wiring (wire breakage, shorting), faulty logic card, faulty accelerator adjustment.

Software checks following signals and detects fault when key switch is turned on.
Accel Pedal Angle (CN1-33)
Accel Switch (CN1-14)
When each condition keeps longer than 2 ms, software detects fault.
When accelerator pedal angle is under 0.2 V or over 4.8 V
When accelerator pedal angle is over 0.3 V and accelerator switch is closed
When accelerator pedal angle is over 1.41 V and accelerator switch is opened
(4) Checks
Check condition when this fault occurred.
When key switch When accelerator pedal When accelerator pedal When error
is turned on is fully depressed is slightly depressed occurs occasionally
(10) Adjust accelerator pedal stroke. (11) Replace accelerator. (12) Replace accelerator.
See "Vehicle Electrical Components" If error recurs, replace
of Chassis Service Manual. logic card.
(5) Check continuity between following terminals and

wire breakage.
CN7-141R - Logic card CN1-39R
CN7-142G - Logic card CN1-33G
CN7-143B - Logic card CN1-37L
CN7-144L - Logic card CN1-14L
Continuity, no breakage No continuity, breakage
(6) Check following two conditions are satisfied. (9) Correct or replace wiring.
• Accelerator switch opens when accelerator pedal
is not depressed.
• Accelerator switch closes when accelerator pedal
is depressed 2 to 3 mm (0.08 to 0.12 in.).
Satisfied Not satisfied
(7) Replace logic card. (8) Adjust accelerator pedal mounting condition.
See "Vehicle Electrical Components" of Chassis
Service Manual.
2-96
211495
2-97
Problem: Right Vehicle Speed Sensor, Abnormality (52)

Indication: “52” display. Faulty right speed sensor circuit. Traction and pump motors disabled.
(1) Situation
Indication: "52" display. Traction and pump motors disabled.
(2) Possible cause

Faulty right speed sensor, faulty right speed sensor wiring (wire breakage, shorting), faulty logic card.

Software detects fault when right speed sensor error input signal keeps more than 200 ms.
(4) Checks
Check resistance between CN16-145Y (yellow) and CN16-146B (black) of right speed sensor. See page 1-67.
Acceptable (1.8 to 2.2 kΩ) Unacceptable
(10) Replace right speed sensor.
(5) Remove logic card cover.

Check continuity between following terminals and shorting to negative (-) side.
CN16-145Y - CN11-145Y - Logic card CN1-43Y (yellow)
CN16-146B - CN11-146B - Logic card CN1-45B (black)
Continuity, no shorting No continuity, or shorted
(6) Check logic card, connector and wiring for abnormality. (9) Correct or replace wiring.
card or wiring.
2-98
211496
2-99
Problem: Left Vehicle Speed Sensor, Abnormality (53)

Indication: “53” display. Faulty left speed sensor circuit. Traction and pump motors disabled.
(1) Situation
Indication: "53" display. Traction and pump motors disabled.
(2) Possible cause

Faulty left speed sensor, faulty left speed sensor wiring (wire breakage, shorting), faulty logic card.

Software detects fault when left speed sensor error input signal keeps more than 200 ms.
(4) Checks
Check resistance between CN15-147L (blue) and CN15-148G (green) of left speed sensor. See page 1-67.
Acceptable (1.8 to 2.2 kΩ) Unacceptable
(10) Replace left speed sensor.
(5) Remove logic card cover.

Check continuity between following terminals and shorting to negative (-) side.
CN15-147L - CN11-147L - Logic card CN1-47L (blue)
CN15-148G - CN11-148G - Logic card CN1-49G (green)
Continuity, no shorting No continuity, or shorted
(6) Check logic card, connector and wiring for abnormality. (9) Correct or replace wiring.
card or wiring.
2-100
211497
2-101
Problem: FC Lever, Abnormality (54)

Indication: “54” display. Faulty operation circuit. Related hydraulic function disabled. (This fault is detected for FC
models only.)
(1) Situation
Indication: "54" display. Related hydraulic function disabled.
(2) Possible cause

Faulty operating lever, faulty lever wiring (wire breakage, shorting), faulty FC controller.

FC controller software checks FC control lever voltage and detects fault.
When fault is detected, FC controller LED flickers and informs main controller of fault.
(4) Checks
Check continuity according to troubleshooting for FC controller. See "Vehicle Electrical Components"
of Chassis Service Manual.
2-102
211498
2-103
Problem: FC Solenoid, Abnormality (55)

Indication: “55” display. Faulty solenoid excitation circuit. Related hydraulic function disabled. (This fault is
detected for FC models only.)
(1) Situation
Indication: "55" display. Related hydraulic function disabled.
(2) Possible cause

Faulty solenoid, faulty solenoid wiring (wire breakage, shorting), faulty FC controller.

FC controller software checks solenoid current when FC control lever is operated.
When fault is detected, solenoid current stops, FC controller LED flickers and informs main controller of fault.
(4) Checks
2-104
211499
2-105
Problem: FC Controller, Abnormality (57)

Indication: “57” display. Faulty FC controller. All hydraulic functions disabled. (This fault is detected for FC models
only.)
(1) Situation
Indication: "57" display. All hydraulic functions disabled.
(2) Possible cause

Faulty FC controller, faulty wiring (wire breakage, shorting) between FC controller and main controller.

Main controller software checks signals from FC controller and detects fault when all signals become open.
(4) Checks
2-106
211500
2-107
Problem: Direction Lever and Accelerator, Faulty Setting (E)

Indication: “E” display. Vehicle operation disabled.
(1) Situation
Indication: "E" display. Vehicle operation disabled.
(2) Possible cause

Key switch turned on while direction lever was left either in forward or reverse position. Key switch turned on while
accelerator pedal was depressed. Faulty direction lever switch, faulty accelerator, faulty logic card.

Software checks following signals and detects fault when key switch is turned on.
Forward Sig (CN1-5) Accel Switch (CN1-14)
Reverse Sig (CN1-6) Accel Pedal Angle (CN1-33)
(4) Checks
Shift direction lever to neutral, and release accelerator pedal. Turn on key switch again, shift direction lever to
forward or reverse, then press accelerator pedal.
No change Vehicle operates
(5) Use self-diagnosis function to locate faulty circuit or (7) Proper starting procedure requires that direction lever
component. See page 1-16. be in neutral position and accelerator pedal be in OFF
position when key switch is turned on.
(6) If faulty component cannot be located, replace logic

card.
2-108
211501
2-109
Problem: Seat Switch, Faulty Setting ((E))

Indication: Flashing “E” display. Vehicle operation disabled.
(1) Situation
Indication: Flashing "E" display. Vehicle operation disabled.
(2) Possible cause

Operator not seated, faulty seat switch (option), wire breakage, faulty logic card, open circuit in seat switch.

Software checks following signal and detects fault when key switch is turned on.
Seat Switch (CN1-9)
(4) Checks
Disconnect battery plug. Remove logic card cover. Disconnect connector CN1. Check continuity between harness
connector CN1-9Y (yellow) and CN1-22G (green). Circuit must close when seat is pressed, and must open
when no force is applied on seat.
No continuity Continuity
(5)With seat pressed, check continuity between seat switch (10) Replace logic card.
wires 111-Y (yellow) and 110-G (green) on switch side.
(6) Check continuity between seat switch harness 111-Y (9) Correct connector contacts or replace seat switch.
(yellow) and logic card CN1-9Y (yellow), and
between 110-G (green) and CN1-22G (green).
2-110
211502
2-111
Problem: Lift Lever, Faulty Setting (H1)

Indication: “H1” display. Lift operation disabled. (This fault is detected for MC models only.)
(1) Situation
Indication: "H1" display. Lift operation disabled.
(2) Possible cause

Key switch turned on while lift lever was in ON position, faulty lift lever switch, faulty logic card.

Software checks initial condition of lift lever switch when turning on key switch and detects fault if lift lever switch
is closed.
Lift Lever SW. 0 (CN1-16)
Lift Lever SW. 1 (CN1-17)
(4) Checks
Set lift lever to OFF, then to ON again.
No change Lift function operates
(5) Use self-diagnosis function to locate faulty circuit or (7) Proper starting procedure requires that lift lever
component. See page 1-16. be in OFF position when key switch is turned on.

card.
2-112
211503
2-113
Problem: Tilt Lever, Faulty Setting (H2)

Indication: “H2” display. Tilt operation disabled. (This fault is detected for MC models only.)
(1) Situation
Indication: "H2" display. Tilt operation disabled.
(2) Possible cause

Key switch turned on while tilt lever was in ON position, faulty tilt lever switch, faulty logic card.

Software checks initial condition of tilt lever switch when turning on key switch and detects fault if tilt lever switch
is closed.
Tilt Lever SW. (CN1-18)
(4) Checks
Set tilt lever to OFF, then to ON again.
No change Tilt function operates
(5) Use self-diagnosis function to locate faulty circuit or (7) Proper starting procedure requires that tilt lever
component. See page 1-16. be in OFF position when key switch is turned on.

card.
2-114
211504
2-115
Problem: Attachment 1 Lever, Faulty Setting (H3)

Indication: “H3” display. ATT1 operation disabled. (This fault is detected for MC models only.)
(1) Situation
Indication: "H3" display. ATT1 operation disabled.
(2) Possible cause

Key switch turned on while ATT1 lever was in ON position, faulty ATT1 lever switch,
faulty logic card.

Software checks initial condition of ATT1 lever switch when turning on key switch and detects fault if ATT1 lever
switch is closed.
Aux 1 (CN1-19)
(4) Checks
Set ATT1 lever to OFF, then to ON again.
No change ATT1 function operates
(5) Use self-diagnosis function to locate faulty circuit or (7) Proper starting procedure requires that ATT1 lever be
component. See page 1-16. in OFF position when key switch is turned on.

card.
2-116
211505
2-117
Problem: Attachment 2 Lever, Faulty Setting (H4)

Indication: “H4” display. ATT2 operation disabled. (This fault is detected for MC models only.)
(1) Situation
Indication: "H4" display. ATT2 operation disabled.
(2) Possible cause

Key switch turned on while ATT2 lever was in ON position, faulty ATT2 lever switch,
faulty logic card.

Software checks initial condition of ATT2 lever switch when turning on key switch and detects fault if ATT2
lever switch is closed.
Aux 2 (CN1-20)
(4) Checks
Set ATT2 lever to OFF, then to ON again.
No change ATT2 function operates
(5) Use self-diagnosis function to locate faulty circuit or (7) Proper starting procedure requires that ATT2 lever be
component. See page 1-16. in OFF position when key switch is turned on.

card.
2-118
211506
2-119
Problem: FC Controller Lever, Faulty Setting (H5)

Indication: “H5” display. Faulty operating lever setting. All functions disabled. (This fault is detected for FC models
only.)
(1) Situation
Indication: "H5" display. All functions disabled.
(2) Possible cause

Operating lever not in proper neutral position, faulty wiring (wire breakage, shorting) of lever, faulty FC controller,
faulty FC control lever.

FC controller software checks FC control lever voltage and detects fault.
When fault is detected, FC controller LED flickers and informs main controller of fault.
(4) Checks
2-120
211498
2-121
Problem: Data Communication, Abnormality (60)

Indication: “60” display.
(1) Situation
Indication: "60" display.
Vehicle operation enabled Vehicle operation disabled
(2) Possible cause (9) Possible cause

Faulty display, faulty wiring, faulty logic card. Faulty wiring, faulty logic card.
(3) How the error code is triggered (10) Checks

Display unit checks following signals and detects fault Connect battery plug. Turn key switch on, then check
when display unit cannot communicate with logic card. voltage between logic card CN1-1R (red) and logic card
Display TXD (CN1-59) CN2-63B or 64B (black). Checked voltage should be
Display RXD (CN1-61) same as battery voltage.
Voltage acceptable Voltage unacceptable
(4) Checks
Disconnect battery plug. Check continuity between (11) Check logic card. (14) Correct or replace
display CN4-149W (white) and logic card CN1-59W Remove logic card cover. wiring or related
(white), and between CN4-150B (black) and CN1-61B Connect battery plug and turn devices.
(black). key switch on, then check
Continuity No continuity LED (green) on logic card.
Flashing No fashing
(5) Check logic card. (8) Correct or replace

(Tr1 on logic card may be wiring. (13) Replace logic card. (D9 on logic card
defective. See page 1-34.) may be defective. See page 1-34.)
(12) Data communications error and other defects have

(6) Replace display unit. (7)Replace logic card. occurred simultaneously. At first, check data commu-
nications by using the procedures above. After repair-
ing data communications, confirm error code and
troubleshoot by using its own checking procedure.
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Problem: EEPROM, Abnormality (61)

(1) Situation
(2) Possible cause

Faulty EEPROM. During access to EEPROM, some faults occur. Faulty logic card.

When logic software starts, first it reads the Setup option data and then the check sum data from the EEPROM.
The software compares both data. When there is difference, error 61 occurs.
(4) Checks
Set "default values" (See page 1-16). Turn off key switch, then turn on key switch again.
"61" display remains Normal vehicle operation
(5) Replace logic card. (6) Vehicle operates normally.
2-124
Problem: Logic Card, Faulty Initial Setting (65)

(1) Situation
(2) Possible cause

Faulty DIP switch (DSW) setting on logic card, model selection not set, faulty logic card.

Software checks DSW2, 3 and 8 settings and detects fault if settings are not correct.
(4) Checks
Check that DSW2, 3 and 8 settings correspond to vehicle type. If vehicle model is not set, make setting.
See page 1-23.
(5) If correct settings do not solve problem, replace logic

card.
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Problem: Controller, Abnormality (66)

(1) Situation
(2) Possible cause

Faulty logic card (faulty logic circuit, faulty microprocessor MPU, faulty memory, faulty initial setting).

Software checks ROM and RAM and detects fault.
(4) Checks
Perform initial adjustment of controller. (Set default values. See page 1-19.)
"66" display remains Normal vehicle operation
(5) Replace logic card. (6) Vehicle operates normally.
2-126
Problem: Battery Voltage, Excessively Low (68) (For 48-V Vehicles Only)
(1) Situation
Indication: "68" display. Vehicle operation disabled. Low battery voltage. Faulty battery discharge indicator (BDI)
circuit.
(2) Possible cause

Discharged battery or faulty battery, faulty logic card, faulty BDI adjustment.

When key switch is turned on, software checks battery voltage and detects fault if it is less than 42V.
(4) Checks
Connect battery plug. Turn key switch on, close seat switch, then check voltage between line contactor (POS)
and NEG. Checked voltage should be 42 V or higher.
Voltage acceptable Low voltage
(5) Adjust battery discharge indicator (BDI) according to (6) Check battery connection, and charge or replace battery.
specification.
Adjust dial on logic card (See page 1-15, "Setting").
If BDI cannot be adjusted, replace logic card.
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Problem: Steering Sensor, Abnormality (80)

(1) Situation
(2) Possible cause

Faulty logic card setting.

Software detects fault when steering sensor signal is input though truck model is 4-wheel truck.
(4) Checks
Check Dip-SW setting on logic card. See page 1-23.
Dip-SW4: OFF Dip-SW4: ON
(5) Replace logic card. (6) Reset Dip-SW4 for OFF setting.
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EP16K Controller

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Service Manual

For use with EP16K-EP20KC Chassis Service Manual. 99759-69100

Safety Related Signs

The following safety related signs are used in this service

Indicate a specific potential hazard

Indicate a specific potential hazard

Indicates a condition that can cause

Pub. No. 99759-69100

Disassembly diagram (example)

Procedures are described in the text.

Suggestion for disassembling

Item SI unit Customary unit

GROUP INDEX Items

Outline, Controller components, Logic card components, Controller models,

Motor installation positions, Specifications, Structures, Tightening of high-power

Controller Components (Part 1)

1 Logic card 6 Line contactor

Controller Components (Part 2)

1 Hydraulic system diode (D1P) 5 Drive system IGBT (T1R)

Logic Card Components

Odd number pins on tops.

1 Selector switches (SW1 to SW8) 4 CN2 connector (Pin Nos. 23 to 38)

(1) The following controller model is used on this lift

Voltage Hydraulic control Remarks

(2) The DSWs of the logic card are set according to

Truck Models 1 ton class 2 ton class

Operation Outline Drive System

(1) Power ON, default condition Neutral Position

Drive Motor’s Current Table

High power mode

Shunt Current Table

High power & Standard & Economy mode

Thermal & Battery [0] mode

Brake Limit mode

Setting Application Function Default value

M: Medium F: Fast S: Slow

Regeneration (3) Regeneration mode priority

(2) Regeneration modes

Lever Regeneration Characteristic

Shunt Current Table

Range 3 & 4 & 5

Auto Regeneration Characteristic

Shunt Current Table

Range 1 & 2 & 3

Hydraulic System (4) Priority

0 0 1 1 0 Not all levers in neutral or OFF position at power ON.

0 0 1 1 1 Seat switch OFF at power ON.

***: Except 110 and 111

Fail-Safe System Simultaneous operations — Cargo handling

(2) Output power control

(3) Output limit control

Overheat Chat Timer (SUO #24)

(3) Controller overheat (Error code E3)

(2) Pump motor brush wear (Error code E6)

Output Power Control During Braking

Malfunction Data Record Setting

(2) To delete data

Setup Options (4) To set default values

(2) To select option # and set data Self-diagnosis

Mode DRS switch position Other condition

Other Functions Display Unit

(1) Service indicator (SUO #10) BDI (Battery Discharge Indicator)

(2) Auxiliary input for function control

(2) During setup option setting and self-diagnosis